ML17299B172
| ML17299B172 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 04/04/1986 |
| From: | Taylor J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | Van Brunt E ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR |
| Shared Package | |
| ML17299B173 | List: |
| References | |
| NUDOCS 8604150530 | |
| Download: ML17299B172 (9) | |
See also: IR 05000530/1986003
Text
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Docket No. 50-530
April 4,
1986
Sb04150530
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ADOCK 05000530
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PD~R
UNITEDSTATES
NUCLEAR REGULATORYCOMMISSION
WASHINGTON,D. C. 20555
Arizona Nuclear Power Project
ATTN:
Mr. E.
E.
Van Brunt, Jr.
Executive Vice President
P.
0.
Box 52034
Phoenix,
AZ
85072-2034
Gentlemen:
SUBJECT:
CONSTRUCTION APPRAISAL TEAM INSPECTION 50-530/86-03
Enclosed is the report of the Construction Appraisal
Team (CAT) inspection
conducted
by the Office of Inspection
and Enforcement (IE) on January 13-24
and February 3-14, 1986, at the Palo Verde Unit 3 site.
The Construction
Appraisal
Team was
composed of members of IE, Region V, and a number of consul-
tants.
The inspection
covered construction activities authorized
by NRC
Construction Permit CPPR-143.
This inspection is the fifteenth in a series of construction appraisal
inspec-
tions conducted
by the Office of Inspection
and Enforcement.
The results of
these
inspections
are being used to evaluate
the management
control of
construction activities and the quality of construction at nuclear plants.
The enclosed report identifies the areas
examined during the inspection.
Within these
areas,
the effort consisted primarily of detailed inspection of
selected
hardware
subsequent
to quality control inspections,
a review of
selected portions of your guality Assurance
Program,
examination of procedures
and records,
and observation of work activities.
Appendix A to this letter is an Executive
Summary of the results of this
inspection
and of conclus'ions
reached
by this office.
The
NRC CAT noted
no
pervasive
breakdown in meeting construction
requirements
in the samples of
installed hardware
inspected
by the team or in the licensee's
project
construction controls for managing the Palo Verde Unit 3 site.
The
NRC CAT identified a number of deficiencies
which warrant additional
management
attention.
The most significant of these
involves the adequacy of
the design
and construction for masonry block walls which provide support for
and are in proximity to safety-related
components.
Because
these walls were
not assigned
proper quality classification,
inspections
were not performed
as
intended
and the existence
and location of reinforcing steel is in question.
Our concern is that the masonry walls as constructed
may not meet their design
intent.
Me understand that the findings of this inspection will be evaluated to
determine the effects
on Palo Verde Units 1 and 2.
ZE01
Copy to
RCPB~ IE
(
,(
Arizona Nuclear Power Project
Apr:il 4,
1986
Appendix
B to this letter contains
a list of potential
enforcement actions
based
on the
NRC
CA'T inspection.
These are being reviewed by the Office 'of
'nspection
and Enforcement
and the
NRC Region V'Office for aIppropIriate action.
In addition,
Region
V will be following your corrective action foir deficien+
cies identified duringl,-this inspection.
In accordance
with:10 CFR 2.790(a)
a copy of this letter and the enclosure.
will be placed in the
NRC Public Document
Room.
No reply to this letter is
required at this .time.
You will be rIequired to respond to these
findir>gs
after a,decision is made regarding
apjpropriatJe
6nf6rcement action.,
Should you have any questions
concerningl this'nsp'ection,
please
contact
us or
the Region
V Office,.
Sincerely,
Enclosures:
l.
Appendix A, Executive
2.
Appendix B, Potential
3.
Inspection
Report
cc w/enclosures:
See next page'n
es
N Taylor/ Director
+Of ice of, In.'piiftion and Enfoccement
C~
Summary
EnforcIement Actions
Arizona Nuclear Power Project
3
April 4,
1986
cc w/enclosures:
J.
Bynum, Director
Nuclear .Operations
Arizona Nuclear
Power Project
P.O.
Box 52034
Phoenix,
AZ
85072-2034
W.
F. Quinn, Manager of Licensing
Station 4057
Arizona Nuclear Power Project
P.O.
Box 52034
Phoenix,
AZ
85072-2034
T.
D. Shriver,
Manager
Quality Systems
and Engineering
Arizona Nuclear Power Project
P.O.
Box 52034
Phoenix,
AZ
85072"2034
W.
E. Ide, Manager
Corporate
QA/QC
Arizona Nuclear
Power Project
P.O.
Box 52034
Phoenix,
AZ
85072-2034
C.
N. Russo,
Manager
QA Audits/Monitoring
Arizona Nuclear
Power Project
P.O.
Box 52034
Phoenix,
AZ
85072-2034
Jill Morrison,
PVIF
P.O.
Box 24593
Tempe,
AZ
85282
Lynne Bernabei
(Government Accountability Project)
1555 Connecticut
Avenue,
NW
20009
Duke Railsbeck
Arizona Corporation
Commission
1200
W. Washington Street
Phoenix,
AZ
85007
Arthur G. Gehr,
Esquire
Snell
8 Wi.lmer
3100 Valley. Center
Phoenix,
AZ
85073
Arizona Nuclear
Power Project
4
April 4,
1986
Distribution
DCS (Docket No. 50-530)
NRC
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WPaton
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ACRS (10)
Regional Administrators
Regional Division Directors
HBoul den,
OIA
SECY
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OCA (3)
VStello
HDenton
CAT Members
Resident Inspector
RHartfield
Al 1 Licensees
(Distributi on 1S)
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APPENDIX A
EXECUTIVE
SUMMARY'n
announced
NRC .Construction Appraisal
Team
(CAT) inspection
was conducted't
Arizona Public Service
Company's
Palo Verde Nuclear Generating Station
(PVNGS)
Unit 3 during the period January
13-24 and February 3-14,. 1986.
.OVERALL CONCLUSIONS
Hardware
and documentation
.for construction activities were generally in
accordance
with requirements
and licensee
commitments.
However, the
NRC CAT did
identify a number of hardware deficiencies that in most cases
have resulted
from
construction
program weaknesses.
These include:
1.
Masonry walls which support
and are adjacent to safety-related
components
were found by the
NRC CAT to have 'the reinforcing bars not placed in accord-
ance with the design drawings.
In addition, prescribed
inspection
records
were not available to document the adequacy of the masonry wall construction
process
and to support design analysis
assumptions.
This was
due in part to
the fact that the original quality classification of the masonry walls was
incorrect.
The masonry walls were classified
as Class
S which requires
no
special quality requirements
beyond industry standards.
This area will
require further review by the
NRC.
2.
In the mounting of electrical
components,
6 of 11 pieces of gC accepted
equipment
and
5 of 32 gC accepted
cable tray hangers
were found with weld
configurations that did not match specified requirements.
In addition,
the cable tray hangers
had been subject to plant wide reinspection
programs
for,previously identified attachment
design deficiencies.
3.
Based
on field observation of work activity, discussions
with site
engineering
and Westinghouse
personnel,
and
a review of data which
describes
failur'es
and detector
leakage
experienced
-on
PVGNS Units 1
and 2,
NRC CAT inspectors
concluded that the existing qual.ity verification
program was not adequate
to assure that critical ex-core termination
activities are satisfactorily accomplished.
Based
upon
NRC CAT concerns,
the applicable
gC procedure
was revised to specifically detail those
steps for which gC i'nspection is required.
Several
deficiencies in vendor
equipment were identified.
These
were vendor
deficiencies
related to terminations in the diesel
generator control panels
and soldered
connections
in the 125V
DC battery chargers
and had not been
identified during source inspection, receipt inspection,
or field installa-
tion activities.
In addition,
vendor weld deficiencies
.were found in
instrument racks.
AREAS INSPECTED
AND RESULTS
Electrical
and Instrumentation
Construction
In general,
the electrical
and instrumentation installations
examined were found
to conform to applicable
design
and installation requirements.
However, several
areas with hardware
deficiencies
were identified.
A-1
A number of raceway instal.lations
were found not meeting the required separation
criteria.
However, the major efforts of the licensee
s inspection, program for
separation
of Class lE raceway installations is not yet complete.
This area
will require additional
NRC and licensee attention.
Configuration deficiencies
were identified in some cable tray hanger connections
and the mounting welds for some electrical
panels.
Five gC accepted
cable tray
hangers
were found with weld connections
not matching the configuration of
approved designs.
A large percentage
(6 of ll panels
inspected)
of gC accepted
equipment
was found to exhibit deficient mounting configurations.
The mounting
weld configurations
were not in accordance
with the approved design
documents.
The quality of vendor terminations in the diesel
generator
control panels
and
125V dc battery chargers
was found to be inadequate;
The field gC verification of in-process
excore terminations
was found to be
inadequate
and requires additional
licensee attention.
The status of qualification for several
components
of the diesel
generator control
panels
and
some wire types in motor operated
valves requires additional
NRC and
licensee
review.
Mechanical
Construction
Preventive
maintenance
of mechanical
equipment
was found to be in conformance
with requirements
and good maintenance
practices.
Heating, ventilating and air
conditioning hardware (supports/restraints,
duct sections, fire dampers)
were
generally found to be installed in accordance
with requirements
or the deficien-
cies
found by the
NRC CAT had been, previously identified;
However, deficiencies
were identified i.n three areas:
piping, pipe supports/restraints,
and mechanical
equipment.
In the area of piping, improper material
was
used for flange bolting.
Undersized
beam attachment
load pins were used
on pipe supports/restraints.
Mounting hardware
and foundations
on
some
HVAC equipment
were found to be
fabricated
and installed improperly.
These
areas of concern require further
licensee
evaluation.
Weldin
and Nondestructive
Examination
Welding and nondestructive
examination activities were generally found to be
conducted in accordance
with the governing codes
and specifications.
However,
several
examples
were found in which completed structural
welds in pipe supports/
restraints
were smaller than that specified in the design drawings.
Some vendor
supplied tanks
and heat exchangers
were found to have undersized
weld reinforce-
ment in "nozzle to shell" and "manway to shell" joints.
In addition, deficient
welds were found in vendor supplied instrument racks.
The
NRC CAT inspectors
also found a number of vendor radiographs
which did not
have the required film quality.
In the area of Preservice
Examination activities,
the
NRC CAT identified welds which had indications that had not been recorded
as
required
by the licensee's
program.
In the review of some welding procedures,
timely information was not provided
to adequately
determine whether the procedures
properly addressed
ASME Code
provisions in the areas of impact tests of the heat affected zone,
the identi-
fication of non-essential
welding variables,
and the prohibition of peening in
certain situations.
A-2
Civil and Structural
Construction
In the area of masonry block walls, the
NRC CAT identified that prescribed
in-process
inspections
had not been performed..It
was also identified that
reinforcing bars were not positioned= as required, by the design drawings.
The design
and construction
adequacy of the block walls will require further
review by the
NRC.
Structural
steel installation was determined
to- be generally adequate.
Deficient
bolted connections
were found by, the
NRC CAT in containment
column splice
connections.
Design considerations
for thermal loading on structural
steel
members will require further review by the
NRC.
gC documentation for .concrete
placements,
mechanical
splices of reinforcing steel,
containment post-tensioned
tendons,
and structural backfill were generally deter-
mined to be adequate.
Material Traceabilit
and Control
The material traceability and control program is considered to be satisfactory.
No significant deficiencies
were identified in the sample of items selected for
review by the
NRC CAT.
Documentation
was available to indicate that materials
were installed
as specified.
Desi
n Chan
e Control
Design change control
was determined'o
be generally in conformance with
applicable
requirements.
The most significant findings were the lack of docu-
mented,
auditable justification for some safety-related
design
changes
and failure
to assure that design
changes
were
made to all affected design
documents
in a
timely manner.
Corrective Action S stems
In general
the licensee's
corrective action program was found to be acceptable.
However, in the area of cable tray support attachment configuration the licen-
see's
program
has not been effective as evidenced
by additional
examples of
configuration deficiencies
found by the
NRC CAT after several
licensee
reinspection
programs.
A-3
APPENDIX B
POTENTIAL ENFORCEMENT ACTIONS
As a result of the
NRC CAT inspection of January
13-24 and February 3-14,
1986
at the Palo Verde site, the following items are being referred to Region
V as
Potential
Enforcement Actions.
Section references
are to the detailed portion
of the inspection report.
10 CFR 50, Appendix B, Criterion III, as
implemented
by Arizona Public
Service
(APS), Palo Verde Nuclear Generating Station Final Safety
Analysis Report
(FSAR) Section
17. 1A.3, requires that measures
shall
be
established
to,assure
that applicable regulatory requirements
and design
basis
are correctly translated
into specifications,
drawings, procedures,
and instructions.
2.
Contrary to the above, at the time of this inspection,
the licensee's
program
was not adequately
implemented in that masonry block walls were incorrectly
classified
as guality Class
S for which no special
qual:ity requirements
beyond industry standards
are
needed.
Partially due to the "S" quality
classification,
in-process
inspections
were not accomplished.
As a result,
reinforcing steel
was found to be located not in accordance
with the design
drawings
and also inspection records
were not available to support design
analyses
assumptions.
Therefore,
masonry walls may not meet their design
intent.
(Section V.B.1)
10 CFR 50, Appendix B, Criterion VII, as
implemented
by the
Section 17.1A.7, requires in part that measures
shall
be established
to
assure that purchased
material,
equipment,
and services
conform to purchase
documents.
3.
Contrary to the above, at the time of this inspection,
the
NRC CAT inspec-
tors found several
deficiencies in vendor supplied
components
as follows:
a.
Several
installed Class
1E components
exhibited poor workmanship
and
inadequate
.vendor product quality.
These include inadequate
solder
connections
in the dc battery chargers
and
damaged
and broken terminal
lugs in the diesel
generator
control panels.
(Sections II'.B.2.b(4) and
II.B.3.b.(6))
b.
Instrument racks
had various weld deficiencies
such
as incomplete
fusion, missing or undersized
and weld spatter.
(Section IV.B.5)
c.
Some vendor supplied radiographs
did not have the required film quality.
(Section IV.B.11)
10 CFR 50, Appendix B, Criterion X, as
implemented
by the
Section
17. 1A.10, requires that
a program for inspection of activities
affecting quality be establ,ished
and executed to verify conformance with the
documented instructions,
procedures,
and drawings for accomplishing the
activity.
Contrary to the above, at the time of this inspection,
the licensee's
inspection
programs
were not effectively implemented in that:
B"1
a.
Four instances
of undersized
beam attachment
load pins were identified
on two- ASME Class
1 pipe supports
and, two Class
R pipe supports contrary
to design
drawings
and vendor catalogs.
(Section III.B.2)
b.
Improper bolting materials
were identified on flange connections
in
piping installations.
(Section III.B.1)
c.
Six of eleven pieces of gC accepted
Class lE equipment
mounted
by
welding had mounting configurations which were not in accordance
with
the applicable design or specified installation requirements.
In
addition,
5 of 32
gC accepted
cable tray hangers
were found with welded
connection configurations that were not in accordance
with the appli-
cable installation requirements.
(Sections II.B.l.b.(3), II.B.3.b.(4),
(6) and (7))
8-2