IR 05000528/1986021
| ML17300A300 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 07/15/1986 |
| From: | Wagner W, Thomas Young NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML17300A298 | List: |
| References | |
| 50-528-86-21, 50-529-86-21, 50-530-86-15, NUDOCS 8608050286 | |
| Download: ML17300A300 (20) | |
Text
-0 Report Nos.
Docket Nos.
License Nos.
U. S.
NUCLEAR REGULATORY COMMISSION
REGION V
50-528/86-21, 50-529/86-21, 50-530/86-15 50-528$
50-529, 50-530 NPF-41, NPF-46 Construction Permit No.
CPPR-143 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 Site, Wintersburg, Arizona Inspection conducted:
June 9-13 and 23-26, 1986 Inspector:
W.
er, Reacto Inspector y-rs-6 Date Signed Approved By:
. Young, Jr.,
Ch f, Engin rin ection Date Signed Summary:
Ins ection on June 9-13 and 23-26, 1986 (Re ort Nos. 50-528/86-21 50-529/86-21 and 50-530/86-15)
Areas Ins ected:
Routine, unannounced inspection by regional based inspector of licensee action on inspector identified items.
NRC Inspection Procedure 92701 was covered during this inspection.
Results:
No violations or deviations were identified.
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DETAILS 1.
Persons Contacted a ~
Arizona"Nuclear Power Pro ect (ANPP)
~W. E. Ide, Director Corporate QA/QC
- J. Matteson, Quality Monitoring Supervisor
- J. M. Quan, Licensing Engineer J. D. Bayless, QA Engineer W. Gratza, QA Engineer N. Hallas, Senior Systems Engineer'.
P. Indap, Operations Engineer J. P. Wilson, Quality Systems'Engineer b.
Bechtel Power Cor oration (Bechtel)
- D. R. Hawkinson, Project QA Manager
+W. Miller, Construction Engineer
- P. R. Huber, Project Quality Coordinator
- G. Gelinas, Project QC Engineer
- Denotes those attending the exit meeting on June 26, 1986.
2.
Licensee Action on Previousl Identified Items a ~
(Closed) Followu Item No. 50-528/84-45-01
"APS/BPC Audit Checklists" The licensee committed to revise their own and Bechtel's audit checklists to include the resident engineering activities previously omitted.
The inspector's review of APS Audit Report Numbers84-039 and 84-040 revealed that the audit checklists had been revised to include resident engineering activities.
Bechtel Audit No. 13-S-85-3 conducted January 10-15, 1985, included examination of
"Engineering Indoctrination and Training" in accordance with Audit Checklist No. PVS-13.
b.
This item is closed.
(Closed) Followu Item No. 50-529/86-13-P
"Lock Welds Possibl Missin on Check Valves" On December 10, 1985, Anchor Darling Valve Company notified the licensee that some check valves supplied to the V.C.
Summer Nuclear Station were missing lock welds.
Since Anchor Darling also supplied
, check valves to the licensee, Anchor Darling recommended that the check valves be inspected to verify that they have been lock welded.
The licensee actions taken to resolve this potential problem is documented on EER No. 86-XM-006.
Inspections involved disassembling the valves per vendor instruction manuals and inspecting for the missing welds.
This effort included 100 percent of the Unit 2 valves and 10 percent of valves on Units 1 and 3 (3 valves per
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No deficiencies were identified.
Since the initial problem notification, Anchor Darling supplied additional information stating that the V.C.
Summer Nuclear Station valves were manufactured between February 1977 and January 1978, and that the Palo Verde valves were manufactured in the period February 1978 to March 1982.
The licensee concluded that the sample size was sufficient to demonstrate that 'weld deficiencies'dentified in the Anchor Darling letter of December 10, 1985, do not exist in the Palo Verde project valves.
Therefore, the licensee recommended that the remaining valves installed in Units 1 and 3 need not be inspected based on the following: (1) the sample size of 29 out of a total of 69 valves (42K) has revealed no weld deficiencies, (2) the sample size covers the entire spectrum of valve sizes supplied by Anchor Darling to Palo Verde, and (3) the Palo Verde valves were manufactured after the V.C.
Summer valves.
This item is closed.
c.,
(0 en) Followu Item 50-530/86-03-02
"Weld Discre ancies on Cable Tra Su orts" lb The NRC,"CAT identifie'd discrepant weld attachments with 5 of 32 cable'i'ay hangers inspected.
Although the 5 hangers were determined to be technically adequate, additional licensee attention was required to 'assure the acceptability of weld hanger connections.
To accomplish'his, the licensee inspected an additional 100 completed welded conduit supports.
One deficiency was documented on NCR EJ-7897 and dispositioned to use-as-is.
This inspection was performe'd by'Bechtel in accordance with SCIP No. 7090.
The combined
, NRC and licensee inspections included 132 supports with 6 areas of concern.
Only one concern physically affected the hardware and required rework.
Therefore, the licensee concluded that the inspection program was being properly implemented and that no further sampling is required.
'The inspector reviewed the actions taken to prevent recurrence.
This included training welding inspectors regarding attention to detail, specific inspection criteria and techniques to unique problems occurring within the discipline, and QC effectiveness inspections.
This item will remain open pending results of a visual examination and evaluation of cable tray hanger welds by the NRC inspector during a future inspection effort.
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(Closed)
Followu Item No. 50-530/86-03-07
"Class 1E Electrical E ui ment Mountin Deficiencies Class 1E electrical equipment mounting deficiencies identified by t'e NRC CAT inspectors resulted in the reinspection of 27 pieces of equipment by the license.
The NRC"CAT expressed concern with regard to the licensee conclusion that no further reinspection of previous work is necessary.
Therefore, the licensee amended CAR CA-86-0005 to provide for a 100 percent inspection of all attachment welds for Class 1E electrical equipment mounting in Unit 3.
Deficiencies were identified and documented on NCR's which were subsequently evaluated
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by engineering and dispositioned to use-as-is.
This additional licensee action provides adequate assurance that Class 1E electrical equipment is mounted in accordance with approved design documents, or that deficiencies were identified, evaluated by engineering and approved to use-as-is.
This item is closed.
(Closed)
Followup Item No. 50-530/86-03-09
"Environmental ualification of MOV Wirin Documented evidence for environmental qualification of wire used in limitorque motor operated valves was not available for review during
, the NRC CAT inspectio'n.
The qualification reports in question are for both the Rockbestos SIS wire (QR-5804 and 5805)
and Raychem Flamtrol (F-C-4033-1)..
The inspector reviewed the qualification reports on both of these wire types which substantiate material
,qualificat'ion.
The licensee files were updated to include these documents.
This item is closed.
C (Closed)
Followu Item No. 50-530/86-03-10
"Flan e Boltin Material Discre ancies" The NRC CAT identified three instances of improper bolting material in flange connections.
These instances were satisfactory resolved and>> did not appear to be indicative of a major problem as the piping was found generally to conform to applicable design requirements.
However, the use of improper bolting material raised the concern for the need for increased attention to the control and verification of flange bolting materials by Quality Control Engineers (QCEs).
The actions taken to prevent recurrence is documented on CAR No.
CA86-0002.
The corrective action required that training be provided to the QCEs and AFEs on the requirements of Piping Material Classifications including ASME flange bolting material verification, i.e., identification of bolting material, grade and type.
The inspector reviewed the training records which documented that this training was provided to the required personnel.
Specifically, the training sessions addressed the requirements for tightening and torquing of bolted connections utilized in various installations, and the identification of the type of bolts used.
Engineers within the following disciplines received this training: piping, electrical, civil, pipe supports, NCR group, welding, mechanical and nuclear.
The records also show that the mechanical and piping QC engineers received similar training.
This item is close F" RF
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ge (0 en) Followu Item No. 50-530/86-03-12
"Undersized Beam Attachment Pins" h.
Due to the large percentage (1/3) of undersized beam attachment pins identified in the primary sample by the NRC CAT it was recommended
, that this problem be examined in more depth by the licensee.
The licensee responded by reinspecting the last of 195 "Q" class variable spring/rod hangers.
Therefore, the combined NRC CAT and construction reinspection covered 100% (195) of the subject hangers in Unit 3.
This is documented in Bechtel letter B/ANPP-K-20483-Q to ANPP dated May 2, 1986.
Eight additional cases of undersized load pins were documented on NCRs.
Engineering evaluation resulted in a disposition of use-as-is.
This item will remain open pending NRC review of the engineering evaluation to assure that the undersized pins are in compliance with the original code design requiremen'ts.
(Closed)
Followu Item No. 50-530/86-03-13
"Pi e Su ort to Structure Clearances This concern's about whether the necessary attention will be provided to assure that pipe support to structure clearance requirements are met.
The inspector reviewed the licensee response which indicated that the existing program is adequate and that no additional criteria are required.
Assurances that these clearance or interference requirements are satisfied by the licensee's existing programs include; (1) utilization of a 3/4" to 1'cale plastic model during initial design which provides identification of potential interferences between piping and other commodities, (b)
the 79-14 walkdown program which is structured to identify and evaluate any potential conflicts before plant operation, and (c) the thermal expansion testing for the piping verification program which is preceded by a visual check for potential interferences from any anticipated pipe motion, and subsequently monitored during system heatup.
The thermal expansion testing is defined in PETG-6-XX-1; the inspector's review of this guideline revealed that Section 3.1.A requires "all piping systems to be tested are verified to have been inspected to Internal Procedure (IP) 4.37 with no unresolved items".
IP 4.37 includes a check for 2" clearance between pipe and any potential interference for Seismic Category 1 and safety-related piping.
I This item is closed.
(Closed)
Followu Item No. 50-530/86-03-15
"Weldin Procedure A~de cec The NRC CAT identified a concern with supporting procedure qualification record (PQR),'QR No.
892 for welding procedure Pl-AT-Lh CCVN).
The test data recorded on PQR No. 892 indicated a
lower average HAZ lateral expansion value than that of the base material.
The ASME Code requires that the average lateral expansion value of three HAZ specimens be equal to or greater than the average value of the unaffected base metal Charpy V-notch (CVN) specimen.
Also, the rules require that the specimens be tested at a
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temperature lower than or equal to the lowest service temperature.
The test specimens listed on PQR No.
891 were tested at +30'F.
Information supplied to the inspector revealed that the main steam piping system has a lowest service metal temperature of +40'F.
PQR No. 892 which covers the non post weld heat treated case for welding procedure Pl-AT-Lh(CVN) shows that Charpy V-notch specimens were tested at 30'F.
The fact that the Charpy V-notch testing for qualification purposes was done at 10'F less than the main steam piping system application indicates that the application will have improved impact properties when compared to the test results obtained during procedure qualification.
The licensee therefore concluded that no technical concerns exist for the impact properties shown on PQR No.
892 or for the main steam piping system application.
The inspector reviewed PQR No. 892 and the technical justification provided and concluded that the licensee had not violated the rules of NC-4330 of Section III of the ASME Code.
Another concern with PQR No. 892 was that the procedure is qualified for use on materials up to 2 inches thick without post weld heat treatment (PWHT).
The ASME Section III code and Bechtel welding standards require PWHT for base material thickness greater than lf inches.
Therefore, when welding or weld repair is performed to welding, procedure Pl-AT-Lh(CVN) the applicable PQR is No.
695 which covers PWHT, and not PQR 892.
In addition, since the test coupon used was 1 'inch thick, all the lateral expansion values listed on PQR 892 meet the required values given in Table NC-2331-1 of ASME Section III for the thickness range of 3/4 to 13 inches.
Peening was not addressed in the General Welding Standards (GWS) or in the welding procedure specifications (WPS).
The concern was whether paragraph NC-4423.2 of ASME Section III, which prohibits peening on the internal (root) layer and the final layer of the weld was being met. It is a Bechtel standard practice that if a variable, such as peening, is not specifically addressed in any procedures then it is not permitted.
Therefore, since peening is not permitted it is not addressed in the GWS or WPS which is in compliance with ASME Section IIIrequirements.
The NRC CAT noted that ASME Section IX nonessential variables QW-410.1, QW-410.3 and QW-410.5 were not addressed in welding procedures Pl-AT-Lh(CVN), Pl-T, P8-T-Ag and P8-M-PA as applicable.
The inspector reviewed the licensee response to the following concerns associated with these welding variables:
(1)
With respect to variable QW-410.1; GWS specifications require stringer beads for manual welding in the 2G position.
Unless specified on the WPS, all other positions can be stringer or weave beads.
(2)
With respect to variable QW-410.3; the weld data sheets of the applicable PQR's document orifice/cup size.
The weld'ata
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sheets provide supplementary information to the PQR's and provide evidence that QW-410.3 was addressed.
I (3)
With respect to variable QW-410.5; the requirement for interpass cleaning is addressed in GWS-FM, paragraph 4.4.8, the acceptable interpass cleaning methods are addressed in paragraph 4.1.3.
Although paragraph 4.1.3 addresses cleaning prior to fit-up and welding, the methods also are applicable to interpass cleaning.
p Based on the licensee's information provided and the inspector's examination of the information this 'item concerning welding procedure adequacy is closed.
(0 en) Followu Item No. 50-530/86-03-17
"Instrument Rack Weld Discre ancies" The NRC CAT identified several vendor weld discrepancies on C-E supplied transmitter racks.
The conditions identified included incomplete fusion, weld spatter, missing welds and undersized welds.
The licensee actions taken to evaluate these conditions are documented on CAR No. CA86-0017 and DER No. 86-05.
The licensee requested C-E to provide a written evaluation concerning whether or not the hardware as-built configuration is within the parameters of the original equipment qualification tests.
C-E responded by developing a seismic requalification program on a modified wall mounted transmitter rack.
The modified transmitter racks consisted of all the weld deficiencies identified during the CAT inspection; so that these modifications could be considered to be representative of any rack installed at the plant.
The certificate of seismic qualification test completion is documented in C-E letter V-CE-33452 to ANPP dated February 21, 1986.
The certified test results conclude that the transmitter rack as modified, does not yield a noticeably worse seismic response than the rack originally qualified; also that inspection of the racks after testing did not show any cracks or other weld deficiencies.
The seismic requalification program included a floor mounted transmitter rack; this is documented in C-E letter V-CE-33588 dated March 31, 1986.
As result of these tests, the licensee concludes that the racks as installed in Unit 3 have been qualified for their intended use and are structurally adequate in their present condition.
C-E also performed an inspection of all C-E supplied instrument racks in Units 1 and 2.
This inspection revealed three different missing welds which were subsequently seismically analyzed by C-E.
The result was that the racks in their present condition met the seismic criteria as defined for PVNGS.
The root cause for these weld deficiencies was failure of C-E Newington to conform to the welding requirements specified on their drawings.
Also, there was an apparent breakdown in C-E Newington's QC inspection for not identifying these deficiencies.
C-E Windsor
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has written a CAR to C-E Newington requesting action to resolve and prevent these conditions from occurring again.
This item will remain open pending NRC inspector review of licensee vendor inspection program responsibilities regarding this matter.
The inspector met with the licensee representatives denoted in paragraph 1 on June 26, 1986.
The scope of the inspection and the inspectors'indings as described in this report were discussed.
Licensee representatives acknowledged the inspectors'inding U I'
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JUL 22>ss8 Docket Nos. 50-528 50-529 50-530
'rizona Nuclear Power Project P. 0. Box 52034 Phoenix, Arizona 85072-2034 Attention:
Mr. E. E. Van Brunt Jr.,
Executive Vice President Gentlemen:
Subject:
NRC Inspection of Palo Verde Units 1, 2 and 3.
This refers to the inspection conducted by Messrs.
R. Zimmerman, C. Bosted, G. Fiorelli, J. Ball and J. Melfi of this office on May 27, 1986, through June 30, 1986 of activities authorized by NRC License Nos.
NPF-41, NPF-51 and Construction Permit Number CPPR-143, and to the discussion of our findings held with yourself and other members of your staff at the conclusion of the inspection.
Areas examined during this inspection are described in the enclosed inspection report.
Within these areas, the inspection consisted of selective examinations of procedures and representative records, inter-views with personnel, and observations by the inspectors.
Based on the results of this inspection, it appears that one of your activities was not conducted in full compliance with NRC requirements, as set forth in the Notice of Violation, enclosed herewith as Appendix A.
Additionally, paragraph,9 in the enclosed report documents a discrepancy between the inputs used in the seismic calculation for the diesel generator bridge cranes, and those required by the design specification.
This instance of failure to assure that procured equipment satisfies the appropriate design specification is similar in nature to several examples for which a violation was issued following the NRC Construction Appraisal Team inspection conducted earlier this year (50-530/86-03).
A report of the team's findings and a Notice of Violation were transmitted to you on April 4, and June 16, 1986, respectively.
It is our understanding that you have agreed to include your assessment, and corrective actions associated with the adequacy of the diesel generator bridge crane design verification as part of your response to Item 2, in the Notice of Violation issued on June 16, 1986.
Also, it is our understanding that you have agreed to respond to that Notice of Violation, in total, by the revised date of July 28, 198 Kl" I'! << I)l, I
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JlJL 22 I986 Your response to this Notice is to be submitted in accordance with the provisions of 10 CFR 2.201 as stated, in Appendix A, Notice of Violation.
In accordance with 10 CFR 2.790(a),
a copy of this letter and the en-closure will be placed in the 'NRC Public Document Room.
The response directed by this letter and the accompanying Notice are not subject to the clearance procedure of the Office of Management and Budget as required by the Paperwork Reduction Act of 1980, PL 96-511.
Should you have any questions concerning this inspection, we will be pleased to discuss them with you.
Sincerely, Ol'igiflcf signed ~
D. I', girsA,.
D. F. Kirsch,, Director Division of Reactor Safety and Projects Enclosures:
A. Appendix A Notice of Violation B. Inspection Report Nos.
50-528/86-20 50-529/86-20 50-530/86-14 cc w/enclosures:
J.
G. Haynes, Vice President, Nuclear Operations J.
R. Bynum, PVNGS Plant Manager W.
F. Quinn, Manager, Nuclear Operations Licensing T.
D. Shriver, Manager, Compliance W.
E. Ide, Manager, Corporate QA/QC C.
N. Russo, Manager, QA Audits/Monitoring Arthur C. Gehr, Esq.
Ms. J. Morrison Ms. L. Bernabei, GAP D. Railsback, Arizona Corporation Commission bcc w/enclosures:
RSB/Document Control Desk (RIDS); Resident Inspector; Project Inspector; G. Cook; B. Faulkenberry; J. Martin bcc w/o enclosure 2:
LFMB egion V
I" Zimmerman/dot CBosted GFiorelli JBall JMelfi L li ler AChaffee 7/
/86 7/
/86 7/
/8 7/
/86 7/~6 7678/86
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