IR 05000529/1985015
| ML17299A318 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 05/13/1985 |
| From: | Miller L, Wagner W, Thomas Young NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML17299A317 | List: |
| References | |
| 50-529-85-15, 50-530-85-11, NUDOCS 8506050383 | |
| Download: ML17299A318 (16) | |
Text
8506050383 8505i4 PDR ADOCK 05000529 Q
PDR U.S.
NUCLEAR REGUL'ATORY COMMISSION Report Nos.
Docket Nos.
REGION V
50-529/85-15 and 50-530/85-11 50-529 and 50-530 Construction Permit Nos.
CPPR 142 and 143 Licensee:
Arizona Nuclear Power Project P.
O. Box 52034 Phoenix, Arizona 85072-2034 Facility Name:
Palo Verde Nuclear Generating Station - Units 2 and
Inspection at:
Palo Verde Site, Mintersburg, Arizona Inspection Conducted:
April 8-12 and 22-26, 1985 Inspector:
Approved by:
gner, Rea or nspecto T. Young, Jr.
Ch f D
e S
ned W-/o- $5 Date Signed En eerin ec n
5: 0-ls L. F. Mille,
r., Chief, Reactor 'Prop cts Section
Date Signed
~Summar:
Ins ection on A ril 8-12 and 22-26 1985 (Re ort Nos. 50-529/85-15 and 50-530/85-11)
Areas Ins ected:
Routine unannounced inspection by a regional based inspector of activities associated with implementation of the licensee's Unit 2 gA Program relating to procurement and records control, and with installation of the Unit 3 reactor vessel and reactor vessel internals.
The inspection involved 72 inspector-hours by one NRC inspector.
Results:
No violations of NRC requirements or deviations were identifie II
.
'I PL lk Ib
Details l.
Persons Contacted a.
Arizona Nuclear Power Pro'ect (ANPP).
8E.
"D
"W-L.
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IE='-C.
'A wJ 8C.
M.
J.
J.
V.
E. Van Brunt, Jr. Executive Vice President Karner, Assistant Vice President Nuclear Production E. Ide, Corporate QA/QC Director A. Souza, Assistant Corporate QA/QC Manager G. Penick, Quality Monitoring 'Supervisor N. Russo, Manager Quality Audits and Monitoring Fullmer, Vendor Quality Supervisor R. Matura, Procurement Quality Supervisor N. Tench, Manager Administrative Services R. Emmett, Compliance Engineer Provost, QA Engineer Bayless, QA Engineer Ritter, Supervisor Purchasing S.
Rhodes, Supervisor Records Management b.
Bechtel Power Cor oration (Bechtel')
N~D. R. Hawkinson, Project QA Manager S.
M. Nickell, Project Superintendent T. L. Horst, Project Field Engineer W. Skillicon, QA Engineer c.
Combustion En ineerin Inc.
(CE)
R. Talbot, Newington Site Manager L. Croteau, QA/QC Engineer W. Darbyshire, Field Services Department Engineer Denotes those attending the exit interview on April ll, 1985.
Denotes those attending 'the exit interview on April 25, 1985.
A Pro ram - Procurement Control" I
Four purchase orders and the associated".purchase requests were randomly selected from recently received safety-related ite'ms.
The purchase order numbers were 33500778, 60094333, 60094338 and 60094340.
All items purchased were:from qualified vendors and the procurement documents contained requirements for the vendor/supplier 'to (a) supply, appropriate documentation of qual'ity, (b)'rovide sufficient technical requirements, (c) provide traceability and (d) state, applicability of Part 21.
Review of how these procurement documents were prepared and processed revealed that the System Purchase Request"s (SPR's)
were not prepared in accordance with procedure 3N513.09,.00
"System Purchase Request (SPR)
Preparation and Processing",
Revision '0 of November 9, 1984.
The procedure requires that Inventory Control, Maintenance Engineering and
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Nuclear Engineering, when required,. to approve the SPR.
However, no signature blocks are provided for all'hese signatures.
The inspector observed'hat Maintenance Engineering/Nuclear Engineering is signing in the block reserved. for Inventory Control, and Inventory Control is signing in the.block which is not to be used.
This is not a safety concern since all the required review, and approval's where evident on the SPRs.
In order to correct this discrepancy the licensee has. revised the procedure (Revision 1 of April ll, 1985) to reflect the current practice by allowing, Maintenance Engineering and/or:Nuclear Engineering to sign in the first Inventory approval block and Inventory Control will sign in the second block.
Revision 1 will be in effect until,new SPR forms are issued along with a revised procedure.
The Approved Vendors List (AVL).was'eviewed to assure that the list was being properly maintained in accordance with administrative procedures including the method'or updating the list.,
New vendors quality assurance programs are being reviewed by Vendor equality prior to being placed on the AVL.
Each vendor file contains a Vendor Evaluation Form and. a Vendor Requalification Form which provides documentary evidence of an annual vendor reevaluation.
The results of vendor surveys and evaluations were reviewed by the inspector for the following vendors selected from the AVL:
AVI Corporation, ARG Engineering, Conam Inspection, Texas Bolt Company, Borg-Warner and Marathon Steel.
The vendor surveys where performed, utilizing a survey plan and checklist, in. accordance with procedure gADP 7.1 "Vendor Survey".
The Vendor Inspection Reports appeared,to be accurate and thorough.
Each survey result contained a summary of the gA Program review including an implementation evaluation statement.
No violations of NRC requirements or deviations were identified.
A Pro ram - Records - Unit 2 The inspector reviewed implementation of the QA Program relating to the control of records, for conformance with the Technical Specifications, FSAR and ANSI N45.2.9 requirements.
The transfer of records.
was not complete,
'however,, the majority, of documents to be received, stored and indexed have been or.are in process of being identified.
The following types of records were located in the storage area and examined by the inspector:
Surveillance Test, Fire Protection, gA Training, (}A Inspection, Startup Department Instructions, Preservice Eddy Current Examination, ALARA Reviews,, Plant Review Board Meetings and Fire
. Protection Activities.
The records were stored'n suitable shelving, in folders or binders in a predetermined location allowing for rapid retrievability.
The records of inspection or test were further examined to verify that the records included the following information:
'a
~
b.
c ~
d..
e.
Date of inspection or test.
Identification of item inspected or tested.
Identity of the inspector.
Data recorder and/or evaluator.
Type of inspection or tes ~
~
ly
f.
Results of the inspection or test.
g.
Acceptability.
h.
Action taken in connection with any deficiencies noted.
All documentation included in these record packages were satisfactory.
The records index is being established as records are being identified for turnover.
The index syst'm used by Bechtel includes sufficient identifying information to be compatible, with the index system used by the licensee for final storage of records.
The inspector reviewed procedure number 78AC-OZZ06, "Document/Record Turnover Control", Revision 1 of July 5, 1984.
This procedure contains provisions required for maintaining the records identified in A.l through A.5, in ANSI N45.2.9.
The storage procedure also identified the records storage custodian, the person designated with responsibility for enforcing the storage procedure, accountability of records removed from the storage area, and disposal of superseded records.
'The inspector was informed that no records will be retained by vendors upon completion of construction.
All records, such as radiographs of shop welds of the reactor vessel, will come under the custody of the licensee.
The Supervisor in charge of records storage was interviewed to verify that retention period controls were understood.
Specifically, retention requirements established in Section. 6.10 of.the Technical Specification, and those provided in Appendix A to ANSI N,'45.2.9.
The physical features of the record storage facilities were inspected for compliance with FSAR commitments.
Emphasis was on verification of the exceptions to ANSI N45.2.9 storage facility requirements.
The exceptions incorporated into vaults 1,2, and 3 verified during this inspection were, (a) installation of certified two-hour minimum fire-rated doors, (b)
vinyl-asbestos floor tile in lieu of surface sealant, and (c)
a Halon suppression system.
-Documentation reviewed revealed that the Halon, system for the record storage vaults at the Administration Annex Building were certified acceptable for operation.
Temperature and humidity controls where installed and being maintained within acceptable limits.
This inspection also included a review.of the audit program established to assure that the quality assurance records'torage system is effective.
This was for compliance to ANSI N45.2.9-1974,,Section 5.7 which requires periodic audits to assure, (a) that records maintenance
'nd controls are adequate,(b)
that facilities are in good condition and that temperature/humidity controls and protective devices are functioning properly, and (c) that documents are not deteriorating due to improper storage or rough handling.
Review of audit reports and audit schedules indicated that the.audit performed on November 20 through December 7,
1984 (Audit Report No.84-041)
covered retrievability of records, and the audit scheduled for August 1985 will cover retention and'aintenance.
These audits are scheduled to be performed once every two years.
The inspector's concern was that the present audit program would not meet the intent of ANSI N45.2.9 requirement for periodic audits.
The licensee
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'I
responded satisfactory to this concern by the following two actions.
First, the ANSI N45.2.9 Section 5.7 audit requirements are to be included in the audit checklist scheduled for August 1985.
Second, the equality Monitoring Department will monitor these items on a quarterly basis.
No violations of NRC requirements or deviations were identified.
Weldin Material Control - Unit 3 The inspector reviewed the program established for the handling and control of welding materials for compliance with ASME and AWS Code requirements.
These requirements are applicable to all welding activities including reactor coolant loop piping, other safety-related piping, and structural welding inside and outside the containment building.
Welding materials are purchased in accordance with the requirements of WFMP-1 "Welding Fi;lier Material Procurement Requirements" Revision 3 of June 1,
1977.
The following wel'ding material purchasing and receiving records were reviewed to assure that these activities were conducted in conformance with WFMP-1 and material specifications:
Bechtel P.O.NO.
MRR No.
Weld Filler Material F-166108 F-171665 F-131406 F-138607 183662 196441 116112 130998 E 11018 E 7018 E 308L E 308L The certified material test reports provided the results of the chemical analyses and mechanical property tests as required by the applicable specification.
The record's also included the ferrite requirements for austenitic filler materials (E308L) of both the vendor and in-house measurements.
The requirements for receipt, inspection, storage and disbursement of welding filler materials are in WFMC-l, Revision 6 of February 24, 1978.
WZMC-1 contains storage requirements for environmental (moisture) control, and electrode holding oven temperature limits.
The requirements for the issue, use and return of weld filler materials are effective for limiting electrode moisture pickup and for maintaining identification after the welding materials are issued to the welder.
The welding materials stored in the warehouse and the rod issuing stations were properly identified as acceptable material by (}C inspectors.
Each weld issuing station supporting Unit 3 welding activities was inspected for compliance with,the approved procedures.
All welding materials were properly controlled, holding ovens were within the specified temperature range, and unused welding materials were returned to the rod room, unused low hydrogen covered electrodes were placed in reheat ovens for a minimum of eight hours prior to re-issue.
No Violations of NRC requirements or deviations were identifie igi.
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5.
Reactor Vessel Installation - Unit 3 Installation of the reactor vessel was. completed prior to this inspection.
Installation techniques were observed and reported, in NRC Report No. 50-530/82-07.
A review of the documentation covering reactor vessel storage and installation inspections are discussed in Section 7 of this report.
6.
Reactor Vessel Internals Weldin
- Unit 3 a
~
Observation of Work The inspector observed field welding of reactor vessel internals being accomplished by CE.for two welding operations; capture welding for the guide lug insert dowel pins, and plug welding of the cap screw dowel pins.
Weld surface preparation was performed to assure that the welding surface was clean and reasonably smooth for
"
welding.
The welding was accomplished utilizing a Site Process Sheet (traveler) which specified the required QA inspection hold points.
The welding material used was in accordance with the material specified.
The weld identification and locations were as specified on CE Drawing No. E-14473-164-003 Revision 3.
The welder's qualification test record was reviewed to assure that the requirements for the welding being observed were in compliance with the ASME Code.
The following CE procedures were applicable to the welding activities observed and subsequently reviewed for compliance with ASME Code requirements:
a.
Procedure No. AS-P-012 "Planning, Issuing, and Control of Welding and Welding Material at Field Locations" Revision 4 of April 5, 1982.
b.
Procedure No. AS-P-014 "Field.Welder (}ualification Testing Procedure" Revision 1 of April 5, 1982.
The storage, handling and control of wel'ding, materials was observed and found to be in compliance wi,th procedure AS-P-012.
a
~
Review of Installation Records The welding operations observed during this inspection were the l'ast scheduled'or installation of the reactor vessel internals.
The flexure weld, that. is welding of the core supp'ort:barrel to the lower support structure, was started and completed in December 1984.
Since'this operation was not observed by the NRC, the inspector revi'ewed the associated records to determine whether the records reflect that work was accomplished consistant with NRC. requirements and licensee commitments, with applicable codes and.standards.
CE performed'lexure welding and monitoring activities in accordance with Site Process Sheet (SPS)
No. 650700.
The SPS
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ij
listed the sequence of operations to be performed including designated QA hold and witness points.
The SPS was reviewed and approved by CE engineering, CE quality assurance, Bechtel and the Authorized Nuclear Inspector.
The SPS indicates that the following operations where verified by QA prior to starting the next operation sequenced:
Inspection of the optical alignment monitoring devices.
Level reading on Core Support Structure.
Cleaning of the flexure weld )oint.
Removal of alignment shims, bolts and nuts.
Liquid penetrant examination of base metal where alignment blocks were removed.
Liquid penetrant examination of weld surface root layer, first 1/3 weld layer, second 1/3 weld layer and the final weld surface.
Visual inspection.of final weld.
The ANPP Quality Monitoring Section Monitoring Report No.
SM 840533 of December 17, 1984 indicates that in process welding of the first 1/3 weld layer was monitored.
The following activities were also monitored and found acceptable:
Current procedures, instructions, and drawings available and followed.
Proper sequence of activities followed, witness and hold points observed.
Certified and/or approved material and equipment used.
Material and equipment properly identified.
Calibration current on test equipment used.
Review of Bechtel quality assurance surveillance reports revealed that Bechtel performed daily surveillance of work activities associated with the flexure welding operation.
Surveillance activities included review of alignment monitoring devices, in process welding, weld and NDE documentation review, review of welders'ertification records, verification of weld filler material type and size, inspection of 20% of root pass, and verification that interpass temperature is not in excess of 350 P.
The inspector's review of these records indicated that enough objective evidence was available to conclude that the flexure welding operations were performed in accordance with applicable specifications, drawings, codes and standard V a
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No violation of NRC requirements or deviations were identified.
7.
Reactor Vessel and Internals Record Review Unit 3 The inspector reviewed a sample of records in order to determine that the licensee/contractor system for documenting safety-related work was functioning properly.
Record packages reviewed were associated with the reactor vessel, reactor vessel closure head, core shroud and lower support assembly, and internals alignment.
The records indicated that the stored equipment was inspected for physical damage, proper storage, cleanliness and housekeeping practices.
The records confirm that specified components, such as the reactor vessel, were installed as.
specified, that the required inspections were performed, and that the required protection was provided'fter installation.
Receipt inspection and material certification records have not been received on the reactor vessel and head, and on some of the reactor vessel internals.
Nonconformance Report
'(NCR) Numbers 658 and 1230 document these, deficiencies.
The inspector noted that the Bechtel ASME QA program requires these components to have quality verification documentation prior to installation that includes as a minimum the applicable Code Data Report.
The Code Data Report was available and reviewed by the inspector along with 'the NCR's.
The NCR's were dispositioned allowing the equipment to be installed with the NCR's remaining open until the proper documentation is received.
The dispositions were reviewed and approved by the Authorized Nuclear Inspector, the Project Pield Engineer, and the QA Engineer.
No Violations of NRC requirements or deviations were identified.
Exit Meetin The inspector met with license management representatives denoted in paragraph 1 on April ll and 25,. 1985.
The scope of the inspections and the inspector's findings as noted in this report were discusse @~i ik
O.