IR 05000528/1985037

Insp Repts 50-528/85-37,50-529/85-37 & 50-530/85-27 on 850923-1104.No Violation or Deviation Noted.Major Areas Inspected:Action on NRC Enforcement Item & Quality Records Re safety-related Piping & Components

ML20137V143
Person / Time
Site:	Palo Verde
Issue date:	11/13/1985
From:	Ball J, Hernandez G, Miller L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
To:
Shared Package
ML20137V128	List: IR 05000528/1985037 ML20137V123
References
50-528-85-37, 50-529-85-37, 50-530-85-27, NUDOCS 8512090477
Download: ML20137V143 (7)

Text

e U. S. NUCLEAR REGULATORY COMMISSION

REGION V

Report No /85-37, 50-529/85-37, and 50-530/85-27 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 Units 1, 2, and Inspection Conduct d: ,

pptf mber 23, - November 4, 198 Inspectors:

G J/ . Herne 4 ~

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.SepiorResidentInspector Date Signed J

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Ball, ident Inspector

//-/]-g3 Date Signed Approved By: k //-/3 6[

L.(I/.'MillerGhief, Date Signed Rehttor Projects Section No. 2 Summary:

Inspection f rom September 23 - November 4,1985 (Report Nos. 50-528/

85-37, 50-529/85-37 and 50-530/85-27).

Areas Inspected: A routine, onsite inspection by the Construction Resident Inspectors of activities related to licensee action on one NRC enforcement item, review of quality records related to safety related piping and safety related components, review of the quality implementing procedures and observation of work on safety related components, and review of pipe support and restraint system testin The inspection involved 152 inspector hours onsite by two NRC Resident Inspector The following I.E. Manual Chapters were utilized during this inspection:

Module Nos. 30703, 49065, 50071, 50073, 50075, 70370B, and 9270 Results: In the areas inspected, no deviations or violations of NRC requirements were identifie DR 051115 ADOCK 05000520 PDH l

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DETAILS 1. Persons Contacted

! Arizona Nuclear Power Project (ANPP)

E. E. Van Brunt, Jr., Executive Vice President

• D. B. Karner, Assistant Vice President, Nuclear Production

• W. E. Ide, Corporate Quality Assurance Manager

• D. B. Fasnacht, Nuclear Construction Manager

W. F. Quinn, Licensing Manager

• R. Bynum, Plant Manager A. C. Rogers, Nuclear Engineering Manager

• F. J. Hopkins, Senior Nuclear Engineer L. A. Souza, Assistant Corporate Quality Assurance Manger

• C. N. Russo, Quality Assurance Audits / Monitoring Manager D. E. Fowler, Quality Control Manager T. A. Shriver, Quality Systems Engineering Manager

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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

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W. W. Montefour, Quality Assurance Engineer  ;

] D. M. LeBoeuf, Quality Assurance Engineer '

• J. D. Bayless, Quality Assurance Engineer o H. L. Green, Quality Assurance Engineer  ;

W. J. Gratza, Quality Assurance Engineer 1 i Bechtel Power Corporation (Bechtel)

• G. A. Hierzer, Field Construction Manager S. M. Nickell, Project Superintendent W. G. Bingham, Project Engineering Manager D. R. Anderson, 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. Mear, Assistant Project Quality Control Engineer R. Ruff, Lead Electrical / Instrumentation Quality Control En G. Griffith, Lead Civil Quality Control Engineer

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R. Hedzik, Lead Mechanical Quality Control Engineer

• C. Berg, Bechtel Construction, General Superintendent

• R. E. Vote, Quality Assurance Engineer

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• S. T. Cozzens, Bechtel Resident Engineer

• Denotes personnel attending the NRC Exit Management Meeting conducted on November 4, 1985.

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The inspectors also talked with other licensee and contractor i

personnel during the course of the inspection.

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2. Plant Status Unit Three: Pre-operational testing of all Class IE and non-Class IE electrical power sopply systems was in progres Additionally, prerequisite and pre-operational testing was in progress on all major systems, except the Reactor Coolant, Safety Injection and Steam i Generator / Main Steam systems.

j Construction completion of Unit 3 is estimated at 98%

by the license . Followup on NP.C Notice of Violation - Unit Nos. I and 2 (Closed) Notice of Violation No. 50-528/50-529/85-01/02: " Failure to assure that welding on HVAC Air Handling Units complied with code and drawing requirements" The inspector had previously identified that HVAC Air Handling Units (AHU) installed in Unit Nos. I and 2 did not conform to welding requirements as specified by code and drawing requirement On January 3,1985, the licensee's engineering staf f determined that, based on Calculation No. 13-CC-ZJ-086, the questionable welds for the Unit No. 1 Air Handling Units could be accepted-as-is, and the welds would perform their intended function. The licensee's subsequent review of the identified discrepancies on the Unit No. 2 Air Handling Units resulted in the issuance a Supplier Deviation Disposition Request (SDDR) No. 3989 and a Startup Work Authorization (SWA) No. 15368 to effect repair of the Air Handling Units. The licensee's own examination of the Air Handling Units in Unit No. 3 resulted in the issuance of The Waldinger Corporation (TWC)

Nonconformance Report No. 1140F/III and 1141F/III to rework the.

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AHU's to bring them into code and drawing complianc '

The licensee's investigation into the cause of the deficiency determined the cause to be personnel error on the'part,of the welder and Quality Control Inspector in'1979. However, to provi,de assurance that no other items similar' to 'this item t existed, the licensee reviewed Waldinger's scope of work, performed a sample ,

reinspection of work in Unit Nos. 2. and 3, and conducted' evaluations of the reinspections performed by the Waldinger inspec' tor Additionally, in response to other NRC and licensee concerns regarding Waldinger's Quality Program,' Waldinger had previously strengthened their training and welding program, to further assure that current work activities were accomplished in accordance with project criteri Based on the licensee's corrective actions as indicated above and the inspector's examination of the licensee's stated actions, this violation is close , _ . - _ ._

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t 4. Safety Related ^ Piping - Review of-Quality Records - Unit No. 3 The inspector. examined safety-related piping records to determine whether (1) the licensee's system for preparing reviewing and maintaining records ~was functioning properly, (2) the selected

, records reflected work accomplishment consistent with NRC requirements and SAR commitments, and (3) the records indicated any

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potential generic problems, management control inadequacies or other

weakness of safety significance. The inspector examined the

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following areas during this inspectio ' Nonconformance Reporting System The inspector reviewed the licensee's system for reporting and dispositioning nonconforming materials, parts, and components i associated with safety-related piping to determine whether the records adequately document the status, handling and disposi-tion of nonconformances and deviations. The inspector examined

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ten nonconformance reports (NCRs) for conformance to Work Plan Procedure / Quality Control Instruction (WPP/QCI) No. 5.0, Revision 29, " Nonconforming Materials, Parts and Components."

The NCRs were found to be legible, complete, and reviewed and approved by qualified personnel and processed in accordance with the licensee's nonconformance procedure. The.NCRs were reviewed by the quality assurance / quality control organizations

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for possible trends and generic implications, and for appropriateness of corrective action. The NCRs were properly identified, stored, and easily retrievabl Qualification of Craft and Inspection Personnel Craft Training and Qualifications l

The area of craft training for construction craft was previously examined in NRC Report No. 50-528/85-02. In that report the inspector concluded that while there was

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very little formal craf t training required at the site,

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field discussions with craft workers during NRC hardware inspections found the craft personnel to be very knowled-geable and proficient at their craf t.

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l Inspection Personnel Training and Qualification The inspector reviewed the licensee's system for the qualification, training, and certification of inspection personnel to determine whether the records adequately documented the status of personnel employed in the in-spection of safety-related piping. The inspector examined the qualification records for ten mechanical and piping Quality Control Engineers (QCE) for conformance with Bechtel Quality Control Procedure No. 8.0, " Qualification

! Certification.and Training of Quality Control Personnel" and ANSI N45.2.6-1978. The records were found to be

current, to support the qualification in terms of

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certification, experience, proficiency, training, and j testing. Additionally, the inspector noted that the Bechtel organization performed a verification of prior employment and experience references (of personnel being certified) to independently authenticate the record materia Audits The inspector reviewed the licensee's contractor (Bechtel Power Corporation) system for conducting internal audits associated with the installation of safety-related piping to determine whether the required audits have been performed in accordance with-the predetermined audit schedule. The inspector examined nine internal audits for conformance with Bechtel Quality Assurance Department Procedure No. 5.0, " Audits and No. 8.1,

Qualification of Auditors / Lead Auditors." The audits examined were found to have been reported in sufficient detail and the followup actions to the audit findings were found to be appro-priate. The inspector noted that findings were trended and a monthly quality assurance report issued to highlight quality ,

matters to upper management. This report is provided to both licensee and Bechtel quality assurance managemen No deviations or violations of NRC requirements were identifie . Safety Related Components - Procedure Review - Unit No. 3 The inspector reviewed the following specification and Work Plan Procedures / Quality Control Instructions (WPP/QCI's) for installation

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of safety related components in Unit 3:

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. Specification 13-MM-510 - Installation Specification for Mechanical Equipment

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WPP/QCI 15 Mechanical Equipment Installation

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WPP/QCI 15 Special Inspections of Mechanical Equipment

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WPP/QCI 15 Alignment of Drive Couplings on Rotating Equipment

. WPP/QCI 2 Maintenance of Materials and Equipment The' inspector found the specifications and work procedures adequate

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to assure accomplishment of component installation in accordance l with applicable technical requirement No deviations or violations of NRC requirements were identifie . Safety Related Components - Review of Quality Records - Unit No. 3 The inspector examined quality records relating to the receipt, storage, installation and subsequent preventive maintenance of

! safety related components installed in Unit 3 to determine if records reflected that items were handled and installed in accor-

! dance with specification requirements and required inspections were

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properly performed, recorded, reviewed and evaluated by qualified personnel. The inspector also reviewed documentation concerning the resolution of nonconforming conditions identified by the licensee during the course of component installatio Recent audits by the licensee in these areas were also reviewed.

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The following components were reviewed for conformance to the i applicable quality assurance documents:

Component Tag N Description

. 3-M-EWA-P01 and 3-M-EWB-P01 Essential Cooling Water Pumps ,

. 3-M-PCA-E01 and 3-M-PCB-E01 Fuel Pool Cooling Heat Exchangers

. 3-M-ECA-E01 and 3-M-ECB-E01 Essential Chillers

. 3-M-EWA-T01 and 3-M-EWB-T01 Essential Cooling Water Surge

! Tanks

. 3-M-AFB-P01 Motor Driven Auxiliary Feedwater j Pump ,

j The inspector reviewed receipt inspection packages, completed

! construction inspection plans and maintenance action cards for each component. The inspector reviewed ten nonconformance reports specifically related to these installations. Review of audits

, performed by the licensee over the past four years in the area of

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safety related component installation revealed no significant I findings.

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No deviations or violations of NRC requirements were identified.

] 7. Safety Related Components - Observation of Work - Unit No.'3 i

1 The inspector observed during the course of this inspection the l installation of the pump impeller into the motor driven auxiliary

feedwater pump 3-M-AFB-P01. The inspector found that activity to be l well controlled, appropriate precautions were taken to prevent

damage during placement, appropriate inspections were conducted and l documented, and personnel appeared knowledgeable and well acquainted j with the work activity.

No deviations or violations of NRC requirements were identified.

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j 8. Testing of Pipe Support and Restraint Systems - Unit No. 2 1 '

) The inspector reviewed completed test packages for the following j testa performed during Hot Functional Testing:

f . 91 HF-2FWO2 - Auxiliary Feedwater Water Hammer Test

! . 91 HF-2ZZ08 - BOP Piping Thermal Expansion Test j The inspector verified that approved procedures were used and that data was properly recorded, and that procedure changes and test exceptions were identified and significant events were recorded in the test log. Other test related activities such as use of calibrated Measuring and Test Equipment (H&TE) and completion of i

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, i test prerequisites were also verified to have been accomplished in

accordance with administrative control procedure '

No deviations or violations of NRC requirements were identified.

l 9. Exit Interview

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f j The NRC inspectors met on November 4,1985, with licensee management 1 i representatives denoted in paragraph 1. The scope of the inspection l

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and the inspection findings as noted in this report were discussed.

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