Text

Package of Documents Used in Preparing Insp Rept 50-317/84-27 Including Handwritten Insp Notes,Draft Insp Rept & List of Persons Contacted During Insp
	ML20128Q426
Person / Time
Site:	Calvert Cliffs
Issue date:	10/15/1984
From:	; NRC
To:	;
Shared Package
ML20128Q416	List: IR 05000317/1984027; ML20128Q413;
References
	FOIA-85-289, FOIA-85-A-26 NUDOCS 8507130430
	Download: ML20128Q426 (97)
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UNITED STATES E

NUCLEAR REGULATORY COMMISSION o

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,I WASHINGTON, D. C. 20555

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' Docket No. 50-317 Baltimore Gas and Electric Company ATTN:

Mr. A. E. Lundvall, Jr.

Vice President - Supply Charles Center Post Office Box 1475 Baltimore, Maryland 21203

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Gentlemen:

SUBJECT:

INSPECTION NO. 50-317/84-27 This refers to the special team inspection conducted by Mr. G. T. Hubbard of this office on October 15-19, 1984, at the Baltimore Gas and Electric Company (BG&E)

headquarters, Baltimore, Maryland, and Calvert Cliffs Nuclear Power Plant, Unit 1, Lusby, Maryland, of activities authorized by NRC License No. OPR-53 and to the discussions of the team's findings with Mr. R. F. Ash and other members of your staff at'the conclusion of the inspection.

The inspection reviewed your efforts to comply with the requirements of 10 CFR 50.49 to implement a program for establishing and maintaining the qualification of electric equipment within the scope of Sai,;cn 2(b) af"10 CFR 50.49.

The inspection also included evaluations X/

of the. implementation of equipment qualification corrective action comm.itments made as a result of the December 16, 1982, Safety Evaluation Report and the October 13, 1982, Franklin Research Center Technical Evaluation Report (TER).

Within this area,'the inspection consisted of selected examinations of procedures and representative records, interviews with personnel, and observations by the inspectors.

This inspection identified significant deficiencies in your implementation of the requirements of 10 CFR 50.49 and your committed actions to resolve the deficien-cies identified in the SER/TER.

Although we are concerned about the serious nature of these deficiencies, no enforcement action will be taken at this time since Unit 1 is not legally required to be in full compliance with 10 CFR 50.49 until March 31, 1985 or the next refueling outage, whichever occurs first.

However, we strongly urge that you carefully review these findings and take appropriate corrective action so as to achieve full compliance with equipment-qualification requirements prior to the March 1985 deadline.

In considering your corrective actions, particular emphasis should be given to assuring

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Baltimore Gas & Electric Company-2-adequate management and Quality Assurance involvement in this important activity.

Your actions relative to these findings will be reviewed during a future inspection, which will also reassess your compliance with 10 CFR 50.49 require-ments and verify that all' committed actions to resolve SER/TER deficiencies have been completed.

-We will gladly discuss any question you have concerning this inspection.

Sincerely, Gary G. Zech, Chief Vendor Program Branch Division of Quality Assurance, Safeguards, and Inspection Programs Office of Inspection and Enforcement Enclosure:

As stated

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Baltimore Gas & Electric Company-2-adequate management and Quality Assurance involvement in this important activity.

Your actions relative to these findings will be reviewed during a future inspection, which will also reassess your compliance with 10 CFR 50.49 require-ments and verify that all committed actions to resolve SER/TER deficiencies have been completed.

We will gladly discuss any question you have concerning this inspection.

Sincerely, Gary G. Zech, Chief Vendor Program Branch Division of Quality Assurance, Safeguards, and Inspection Programs Office of Inspection and Enforcement Enclosure:

As stated DISTRIBUTIGN:

DCS VPB Reading JTaylor JPartlow GZech VNoonan CAnderson UPotapovs GHubbard GHolahan NBLe RLaGrange RKarsch MYost AFinkel LCheung 0Trimble ERichards VPB:0QASIP SC/VPB:0QASIP BC/0RAB:NRR BC/EQB:NRR BC/PS:R1 BC/VPB:0QASIP GHubbard: sam UPotapovs GHolahan VNoonan CJAnderson GGZech i

12/ /84 12/ /84 12/ /84 12/ /84 12/ /84 12/ /84

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U.S. Nuclear Regulatory Commission Office of Inspection and Enforcement

. Report No. 50-317/84-27 Docket No. 50-317 License No. DPR-53 Licensee:

Baltimore Gas and Electric Company Charles Center Post Office Box 1475 Baltimore, Maryland 21203 Facility Name: Calvert Cliffs Nuclear Power Plant, Unit 1 Inspection At: Baltimore and Lusby, Maryland Inspection Conducted:

October 15-19, 1984 Inspectors:

G. T. Hubbard, Equipment Qualification and Date Test Engineer Also participating in the inspection and contributing to the report were:

U. Potapovs, Chief, Equipment Qualification Inspection Section, I&E N. B. Le, Engineer, I&E R. G. LaGrange, Section Leader, NRR R. O. Karsch, Reactor Engineer, NRR M. W. Yost, Consultant Engineer, Idaho National Engineering Laboratory A. Finkel, Lead Reactor Engineer, R1 L. Cheung, Reactor Ehgineer, R1 D. Trimble, Resident Inspector, R1 E. H. Richards, Technical Consultant, Sandia National Laboratory Approved by:

G. G. Zecn, Chief, Vendor Program Branch, I&E Date

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INSPECTION SUMMARY:

Inspection on October 15-19, 1984 (Inspection Report No. 50-317/84-27)

Areas Inspected:

Spacial, announced inspection to review the licensee's imple-mentation of a program per the requirements of 10 CFR 50.49 for establishing and maintaining the qualification of electric equipment within the scope ef-Sa ti e M

p 24-) of 10 CFR 50.49.

The inspection also included evaluations of the implemen-M tation of equipment qualification (EQ) corrective action commitments made as a result of deficiencies identified in the December 16, 1982, Safety Evaluation Report (SER) and the October 13, 1982, Franklin Research Center (FRC) Technical Evaluation Report (TER).

The inspection involved 289 inspector hours onsite.

RESULTS:

The inspection identified seven areas of significant deficiencies relative to the compliance with 10 CFR 50.49 requirements:

(1) qualification files not auditable - Paragraph 4.A.(1)(a); (2) inadequate control and storage of qualification files - Paragraph 4.A.(1)(b); (3) inadequate written documen-tation and implementation of requirements and/or procedures for compliance to 10 CFR 50.49 - Paragraph 4.A.(2)(a); (4) no maintenance program which includes activities necessary to maintain the qualified status of qualified equipment -

Paragraph 4.A.(4). m ' "

' suff4e4ent documeni.ation 1.o enable the NRC te "

N datarmine +%t everall EQ-progre; met the requ h emsnt5 af 10-EFR-50-49- - -

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-Par ;;rc;M ' ^ ;'(E) Slack of sufficient information to allow the NRC to determine A

that SER/TER commitments had been implemented - Paragraph 4.B.; and (7) inadequate A

and inaccurate qualification data files - Paragraph 4.0.

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Details 1.

Persons Contacted 1.1 Baltimore Gas and Electric Company (BG&E)

K. Sebra, Principal Engineer

B. Montgomery, Engineer

A. Marion, Senior Engineer

A. Anuje, Supervisor, Quality Assurance (QA)

M. Eye, QA Auditor B. Daschbach, Associate Engineer S. Parr, Engineering Technician R. Branch, Engineer

L. Dudek, Supervisor, Engineering QA

R. Olson, Principal Engineer

L. Basso, Engineering Analyst R. Sydnor, Supervisor, Electrical and Controls (E&C)'

J. Moreira, General Supervisor, E&C Section

R. Ash, Supervising Engineering

S. Parks, General Supervisor 1.2 BG&E Contractors

R. Bell, Engineer, Bechtel Power Corporation - Gaithersburg, Md.

1.3 Nuclear Regulatory Commission

C. Anderson, Chief, Plant Systems Section, R1 V. Noonan, Chief, Equipment Qualification (EQ) Branch, NRR

G. Zech, Chief, Vendor Program Branch, I&E

J. Partlow, Deputy Division Director, DQASIP, I&E 2.

PURPOSE The purpose of this inspection was twofold.

One purpose was to review the licensee's implementation of the requirements of 10 CFR 50.49 and his committed actions for SER/TER identified deficiencies.

The other purpose was to utilize the inspection as a pilot inspection to evaluate a preliminary version of a 10 CFR 50.49 inspection module being developed for NRC regional office use for inspections of licensees' EQ programs.

Only the findings relative to the licensee's activities are dis. cussed in this report.

" Denotes those present at the oxit interview on October 19, 1984

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BACKGROUND On March 16, 1984, the NRC held a meeting with BG&E' officials to discuss BG&E's proposed methods to resolve the EQ deficiencies identified in the December 16, 1982 SER and October 13, 1982 FRC TER.

Discussions also included BG&E's general methodology for compliance with 10 CFR 50.49 and justification for continued operation for those equipment items for which environmental qualification was not completed.

The minutes of the meeting and proposed method of resolution for each of the EQ deficiencies were documented in May 14 and July 9, 1984, submittals from the licensee.

The TER and the May 14 and July 9 submittals were reviewed by the inspection team members and were used to establish a status baseline for the inspection.

Since Calvert Cliffs Nuclear Power Plant (CCNPP), Unit 1 is not legally required to be in full compliance with 10 CFR 50.49 until March 31, 1985, or the next refueling outage, whichever occurs first, and the inspection was scheduled as a pilot inspection to evaluate a preliminary 10 CFR 50.49 inspection module being developed, no enforcement action is being taken regarding the findings identified during this inspection.

However, the licensee is expected to carefully review these findings and take appropriate corrective action so as to achieve full compliance with 10 CFR 50.49 require-ments prior to the March 1985 deadline.

4.

FINDINGS A.

EQ Program Compliance with 10 CFR 50.49 The NRC inspectors examined the licensee's EQ program for establishing the qualification of electric equipment within the scope of +2ction -

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-2(b) cf-10 CFR 50.49.

The program was evaluated by examination of

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the licensee's qualification documentation files, examination of procedures which control the licensae's EQ efforts, verifying the adequacy and accuracy of the licensee's 10 CFR 50.49 equipment list, and examination of the licensee's program for maintaining the qualified status of the covered electrical equipment, hd u6Te

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inspection findingsf-wMetf are discussed h man detaiP below, and-th82'.h x fact that-BC&E-l: st+H-not-fuHy-4mp4ement4ng-its En program, the, j

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4eam-was-unable-to-determine-that-the-Hcenseels-program meetG-the

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tequirements-of-10-CFR-50-49.

(1) Qualification Files, General y

t,/ c] / * O (a) The NRC inspectors review and evaluation of 16 qualification required by Geotdon-(j(j) of 10 CFR 50.49.

files determined that the files were not auditable as Further defini-g tion of auditability is provided in Section 3 of IEEE-323-1971 and 1974 which describes auditable data as information which is documented and organized so as to be readily under-

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standable and traceable to permit independent verification of inferences or conclusions based on the information.

Of the 16 files examined only two files were found to be detailed

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-3-enough so that the inspectors could independently verify BG&E's conclusions.

However, each of these files did have several discrepancies (see paragraphs 4.D.(7) and (14)).

The documentation and detail in the 14 other files was such that ready understanding of what data, evaluations, and conclusions were documented required a great deal of assistance by BG&E personnel (see discussions in paragraph 4.D. for detailed findings concerning each file reviewed).

The files did not clearly document that evaluations and analysis had been performed regarding specified perform-ance requirements and demonstrated qualified life, or whether or not equipment qualification had actually been determined by BG&E.

In some cases where supporting data was referenced to support the qualification files, there was no method in the file to indicate where the referenced data was located.

In other cases, when questions were raised concerning analysis or documentation, documents were generated during the inspection to justify BG&E's position regarding qualification of the item.

In addition, Electrical Engineering Department Procedure No. 18 (EEDP-18), " Equipment Qualification," dated August 6, 1984, requires the use of Qualification Evaluation Worksheets (QEWs), Qualification Report Review Summary (QRRS)

sheets, and Qualification Maintenance Summary (QMS) sheets for the evaluation of equipment qualification.

The inspectors found that the QEWs and QRRS sheets were not always adequately completed and in at least one case they were not in the files.

QMS sheets also were not in the files (see discussion in paragraph 4.A.(2)(a)).

The NRC will evaluate the auditability of the licensee's qualification files during a future inspection (50-317/

84-27-01).

(b) An inspection of the electrical equipment qualification files by the inspector identified that the records were not controlled and stored as described in ANSI N45.2.9, 1974, titled " Requirements for Collection, Storage and Maintenance of Quality Assurance Records for Nuclear Power Plants." An internal audit conducted by BG&E QA from September 12-October 9, 1984, identified similar findings in this area.

The audit report, No. 84-24-01, for this internal audit

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had been typed and was in the process of being issued during this inspection.

The NRC will review the licensee's action relative to the internal audit findings during a future inspection (50-317/

84-27-02).

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-4-(2) EQ Program Procedures (a) The NRC inspector examined procedure EEDP-18 which provides guidelines for the uniform assessment, evaluation, review, and implementation of activities associated with environmental and seismic qualification of Class 1E equipment for CCNPP.

This procedure describes activities to be performed by the electrical engineering department (EED) as well as describing inputs required by other BG&E departments necessary to support the EED evaluations of the EQ program.

The inspector's review determined that the other departme'ts defined in EEDP-18 to support EED have not implemented requirements and/or procedures that would provide the necessary data to support the criteria of EEDP-18.

As of this inspection, the Nuclear Power Department (NPD) had no specific internal requirement to provide the QMS sheets to EED and, in fact, no completed sheets had been provided to EED.

Without the type of data that is listed in the QMS sheets, EED cannot identify whether or not the installed safety-related equip-ment is being maintained in a qualified condition.

(Addi-tional information on maintainance is discussed in paragraph 4.A.(4)).

Lack of written documentation and implementation of procedures for compliance to 10 CFR 50.49 requirements by various licensee departments was identified as an area of concern relative to BG&E's effective implementation of a 10 CFR 50.49 program.

This item will be evaluated during a future inspection (50-317/84-27-03).

(b) The NRC inspector's review of procedures determined that the

"as-built" EQ status that is maintained by the EED qualifi-cation group has a built-in-delay of a minimum of five months before verification of the "as-built" design can be made.

Discussions with BG&E personnel and examples identified in qualification files indicated that this delay can extend even longer, to a year or more.

When a site modification is desired on a piece of qualified electrical equipment, the EED qualification group will issue a facility change request (FCR) for the modification; however, the FCR is not closed until the "as-built" drawings have been completed and then reviewed by the EED qualification group.

The EQ engineer reviews the "as-built" drawings to establish the actual installation of the modification and to establish the qualification of the modified equipment in the "as-built" condition.

If the "as-built" condition is acceptable to

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-5-allow qualification of the. equipment, then the EQ engineer will close out the FCR and update the 10 CFR 50.49 listing to include the modification design data.

The inspector found this delay to be of concern, since a modified

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or new piece of equipment could be utilized in a safety-r related application for a significant period of time during which its qualification would not have been established nor would it have been included on the 10 CFR 50.49 list.

This area of concern will be reviewed during a future NRC inspection (50-317/84-27-04).

(3). 10 CFR 50.49 List:

The licensee is required to maintain a list of the equipment necessary to bring the plant to hot shutdown in case of an accident.

BG&E has three written procedures dealing with the list now in use.

Quality Assurance Procedure No. 28 (QAP-28)

controls items covered by the QA program and EEDP-4 and 18 govern equipment requiring qualification and control of the list of safety-related equipment.

The inspector's examination of the above procedures and discussions with BG&E personnel. determined that while these procedures control BG&E's "Q" list of safety-related items and a Class IE list which is a sublist of the "Q" list, BG&E does not have any formal documented procedures that control the list of items which specifically fall within the scope of 10 CFR 50.49.

The NRC inspector, however, did verify, by two different methods, the completeness of the 10 CFR 50.49 list.

First, the licensee was ' requested to present a " walk-through" to demonstrate how the list is derived using an example system.

Two examples of safety and non-safety-related equipment, which should have been on the list, were checked and both were on the list.

Secondly, the

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j inspector selected eight representative items from various j

systems.

All selected items were either on the list or a j

satisfactory explanation was provided justifying their omission

from the list.

The licensee has developed an equipment data

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base utilizing a digital computer on which the 10 CFR 50.49 i

list is maintained.

The use of this system greatly facilitated the audit and verification of the equipment list.

On the basis

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of the sample audit no deficiencies were identified in the equip-ment list.

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a.

-6-(4) EQ Maintenance Program:

The NRC inspector reviewed site procedure CCl-211 which described plant preventative maintenance requirements.

The maintenance criteria contained in this documentation was generated from construction maintenance records, vendor data, and maintenance manuals.

To assure that v W fi d maintenance records are up-X

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dated with the information developed by the EED qualification l

group, BG&E is planning to generate QMS sheets as described in EEDP-18.

These QMS sheets will be prepared by the Qualification Maintenance Program (QMP) Working committee.

This committee would have the task of assuring that QMS sheets provide the technical data and schedules to maintain the safety-related equipment in a qualified status.

At the time of this inspection the task of filling out the QMS sheets had not started, l

In addition to the QMS sheets, BG&E has identified other tasks that are required in a maintenance program that would be necessary to assure qualified electrical equipment is being maintained in a qualified status.

These tasks identified by the working committee are:

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Plan for new and replacement equipment Plan for piece part and material replacement

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,JimAM m Maintainselected/systemsorportionthereof[ piping

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and S:t:"aticsAdrawings (P& ids), schematics, parts A /

lists, etc.] in an updated status Verify that NRC Bulletins /Information Notices

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concerning environmentally qualified equipment have been addressed i

The E&C section of NPD in a letter dated September 27, 1984 drafted a proposed plan to establish an overall maintenance

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j programltM -usM cuoylf with th: i terL vi-10 CF 50.4^.' The X'r scope of the letter was similar to the presentation made by BG&E to the NRC in their March 16, 1984 meeting at Bethesda, Maryland.

As of this inspection, the only part of the letter that has been implemented is the establishment of the QMP working f

committee.

In reviewing the task assignments and schedules defined in the letter the inspector determined that unless BG&E management approved the outlined program or one similar to it, within a few weeks of this inspection, BG&E would not meet the

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10 CFR 50.49 implementation deadline.

The NRC will evaluate BG&E's activities in the area of qualifi-cation maintenance during a future inspection (50-317/84-27-05).

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-7-Future inspection items 50-317/84-27-01 through 05 will also be evaluated collectively to determine BG&E's overall compliance with the requirements of 10 CFR 50.49 (50-317/84-27-06).

B.

SER/TER Commitments The NRC inspectors evaluated the implementation of EQ corrective action commitments made as a result of the SER/TER identified deficiencies.

The evaluations were based on the premise that all corrective action commitments had been completed as indicated in BG&E letter to H. R.

Denton, NRR, dated May 14, 1984.

This letter stated that environmental qualification of safety-related equipment was essentially complete.

Based on the evaluations conducted, the NRC inspectors were unable to determine that SER/TER deficiencies had been adequately resolved.

Reasons supporting the above finding include:

(1) Determination by inspectors that 14 of 16 qualification files were not auditable (see discussions of paragraph 4.A.(1)(a)).

(2) The existence of conflicting and confusing data in the qualifi-cation files.

The Dragon solenoid valve file, TER item 95, was particularly confusing in the fact that one document in the file indicated the valve was not qualified while another document indicated it was, if heat shrink sleeves had been installed on valve wiring.

The Dragon file also had conflicting data as to what solenoid valve types and configurations were actually installed in the plant.

(See paragraph 4.0. for detailed discus-sions on Dragon valves and other TER item files reviewed.)

(3) The lack of insulation material data in the qualification file for Allis Chalmers motor, TER item 47.

This data is needed so that irradiation effects on motor insulation materials can be evaluated to establish qualification.

Enclosure 2 to the BG&E

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letter of May 14, 1984 stated that the motor was qualified and documentation was available.

BG&E stated during the inspection

that the required data from Allis Chalmers had not been received,

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but BG&E considered the motor "qualifiable" due to experience with other qualified motors.

(See paragraph 4.D.(9) for detailed discussion on this motor.)

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l (4) The inspectors' identification of System Component Evaluation i

Worksheets (SCEW) discrepancies such as operating time require-ments being identified as nine hours when it should have been 17 days and qualification operating time requirements being

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identified as "Not Applicable" when it should have been at

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least 17 days.

(See paragraph 4.0. for specific identification of instances of these discrepancies.)

(5) The inspectors' identification of five technical issues which were not addressed in the documentation establishing the qualified life of TER item 42, Amphenol electrical penetration assemblies L

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(EPAs).

Enclosure 2 of BG&E letter of May 14, 1984, stated that the qualified life had been established.

(See paragraph 4.0.(7)

for detailed discussion of this TER item.)

The above items led the NRC inspectors to the conclusion that BG&E had not performed adequate reviews and analysis to assure correction of SER/TER deficiencies and/or had not adequately documented the reviews and analysis in a manner readily auditable and acceptable to the NRC.

Until adequate analysis and/or documentation is performed by BG&E the NRC is unable to determine if SER/TER commitments have been completed.

BG&E's implementation of SER/TER commitments will be evaluated during a future inspection (50-317/84-27-07).

C.

Plant Physical Inspection As part of this EQ inspection, the NRC inspectors conducted an inspec-tien on October 18, 1984, at the CCNPP, Unit 1 site at Lusby, Maryland.

Of 16 components that were reviewed by the inspectors at the corporate offices in Baltimore, Maryland, TER items 10, 19, 43, 47, and 95 were selected for inspection verification.

The five items, which were all outside of containment were inspected for:

(1) manufacturer and model number; (2) location, interfaces, and mounting configuration; (3)

condition of installed item; (4) environmental conditions of location; and (5) physical separation.

The information gathered during the plant inspection was compared to documentation reviewed at the corporate offices to verify the accuracy of the documentation.

The following equipment items were inspected:

(1) Main steam isolation valve (MSIV) pilot solenoid valves (ISV4042-46) located in piping area (A224), TER Item 10, Republic /Teledyne.

(2) Feedwater isolation valve (2MOV4517) located in the main steam piping penetration room (A315), TER Item 19, Limitorque.

(3) Low pressure safety injection (LPSI) pump motors (1MA104)

located in the emergency core cooling system (ECCS) pump room (A119), TER Item 43, General Electric.

(4) Containment spray pump motors (1MA107 and 1MA407) located in the ECCS pump room (A119), TER Item 47, Allis Chalmers.

(5) Hydrogen analyzer solenoid valves (ISV6507A thru G) located in the west penetration room (A221), TER Item 95, Dragon.

The model number on item (2) above could not be verified because of

.p. extremely hiah tamnerature and nameplate location.

The type and X

'model numbers could not be verified for item (5) without scaffolding,

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therefore these items were not verified.

No deficiencies were identified by the inspectors during the plant tour.

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Detailed Review of Documentation File The NRC inspection team examined BG&E's qualification documentation

. files for the items discussed in the following paragraphs to verify the adequacy and accuracy of the files in establishing the qualified status of electrical equipment within the scope of 10 CFR 50.49.

(1) The inspector's review and examination of qualification file SV0013 for the Republic /Teledyne MSIV pilot solenoid valves, TER item 10, determined the file did not contain sufficient documents to determine the adequacy of the qualification.

Enclosure 2 to the May 14, 1984, BG&E letter had stated that the valve was qualified and documentation was available.

The inspector's review of the SCEW sheets for these valves indicated that the required operating time, the qualified operating time, the qualified relative humidity, and aging parameters were all identified as "Not Applicable" (NA) or

"Not Required".(NR); however, there was no documented evaluation supporting this position.

(2) The inspector's review and evaluation of qualification file MOV015 for the Pratt motor operated valve (MOV), TER item 15, identified some questions regarding the file; however, when these questions were presented to BG&E, BG&E determined that the Pratt MOV was no longer in the scope of 10 CFR 50.49.

Enclosure 1 to the May 14, 1984 BG&E letter indicated that the valve might be removed from the scope of the rule; however, it was not identified to be removed until the inspector raised questions concerning its qualification.

8G&E said the valve would be removed from the scope of the rule because P&ID No. 60-248-E, M-65, Revision 6, identified that the valve is in the non-safety-related portion of the hydrogen purge system.

(3) The inspector's review and evaluation of qualification film MOV002 for the Limitorque MOV, TER item 19, determined that Limitorque report No. 80058 and Wyle Laboratories report No.

17467, Revision A, were in the file to correct SER/TER identified deficiencies. While there was no documentation in the file which provided traceability to what specific data in the reports was used to satisfy SER/TER deficiencios relative to similarity, aging degradation, and qualified life of the valve, the inspector determined that the reports were adequate to satisfy the deficiencies.

(4) The inspector's review and evaluation of qualification file MOV001 for the Limitorque MOV, TER ftem 27, identified the same concerns discussed under paragraph 4.0.(3) abov _._

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(5) The inspector's review and evaluation of qualification file PT0001 for Fischer and Porter pressure transmitter, TER item 38, identi-fled questions regarding the environment to which these transmitters could be exposed.

BG&E initially responded that the environment was not yet well defined and could be more severe than just a radiation environment; however, after taking a further look at the environment, BG&E verbally told the inspector that these transmitters have now been determined to be out-of-scope of

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10 CFR 50.49.

The inspector took no exception to the deletion of the transmitter from the 10 CFR 50.49 list.

(6) The inspector reviewed qualification file PT0001 for Fischer and Porter pressure transmitters, TER item 41, to verify that commit-ments regarding the TER identified deficiency had been implemented.

The inspector's review determined that FCR-81-1000 had corrected the deficiency by requiring the transmitters to be replaced with model 763 Barton transmitters.

(7) The inspector's review and evaluation of qualification files EPA 001-006 for Amphenol EPAs, TER item 42, identified five areas of concern which were not addressed in the file document-ation.

These concerns are:

(a) Calculated life of BUNA-N gaskets was 0.6 years; however, BG&E stated that operating experience shows BUNA-N has a much longer life.

No supporting data or references were provided in the qualification file to justify a qualified life beyond 0.6 years, nor were any maintenance / surveillance requirements established which could assure an operational life beyond 0.6 years.

(b) Surveillance of gasket materials was specified in qualification files EPA 004 006; however, no informa-tion was provided concerning the frequency of inspection or what the inspector or maintenance personnel should look for.

(c) Similarity between the qualified EPAs and the EPAs actually testod was not adequately addressed in the qualification files.

(d) Self-heating of the ennductors and the effect on aging of materials in the EPAs was not adequately

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addressed in the files.

l (e) Test failures were not adequately addressed in the files.

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(8) The inspectors' review and evaluation of qualification file MTR004 for the General Electric motor, TER item 43, identified the following discrepancies in the documentation:

(a) SCEW' sheets indicated that the required operating time was nine hours; however, Wyle report No. 17467-MTR004, Revision A and BG&E's QEW indicated the required operating time was 17 days.

The SCEW sheets also showed the qualified operating time as NA, which did not meet the above requirement.

The Wyle report did show the qualified life to be greater than 17 days.

(b) The above Wyle report identified that the material most sensitive to radiation used in the subject motors is BUNA-N, which has a radiation service limit of 4X108 rads.

The SCEW sheet identified the qualified radiation of the motor to be 10 x 108 rads.

However, the inspector found the required radiation level to be only 3.8 x 108 rads.

(c) The Wyle report recommended that the BUNA-N in the motors should be replaced at an interval of 4.9 years or less.

SCEW sheet data indicated that BG&E did not agree with the 4.9 year replacement interval and this was verbally confirmed by the inspector; however, there was no documentation in the file to justify a longer replacement time interval.

(9) The inspector's review and evaluation of qualification file MTR006 for Allis Chalmers motors, TER item 47, determined that the motor had not been qualified as stated in Enclosure 2 to the May 14, 1984 BG&E letter.

The enclosure stated that the equipment was qualified and documentation was available.

During the inspection BG&E verbally stated that they considered the motor to be "qualifiable" based on past operating experience, but they had not received the list of materials for the motor thattheyneededtocompletetheirqualificationevalgationfor a specified harsh radiation environment of 3.073 x 10 rads.

Other nt.:essary data, identified by the inspector as not being in tha file included:

(a) Qualification Report Review Summary (b) QualificationEvaluationWorksheets (c) Operability time (d) Qualified life (c) Necessary maintenance to preserve a qualified status

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(10) The inspector's review and evaluation of qualification file TB0001 for Marathon terminal blocks, TER item 58, identified a number of instances where the data in the file was confusing and/or conflicting with other data in the file.

Examples of these instances are:

(a) The SCEW sheet, dated October 15, 1984, states the operating time required and demonstrated are NA; j

whereas, Wyle report 17467-TB0001, Revision 8, dated October 18, 1982, cites a required operating time of 17 days.

(b) Page 18 of the Wyle report quotes A. Marion, BG&E Senior Engineer, as saying the terminal blocks carry both power and instrumentation loads.

The file contains no documentation that identifies the actual application of the terminal blocks.

(c) Wyle report 17467-TB0001 is an evaluation of Wyle test report 45611-1, dated February 24, 1982, for BG&E's applications; however, the test report was not in the files.

If BG&E is relying on this test report to justify qualification, then it should be in the files or BG&E should evaluate it, document the evaluation results, and arrange to have the report available to them for the life of the equipment.

(d) Pages 4 and 5 of QRPS cite data from Wyle test report 45603-1, but it is not clear as to how the report is being used to support qualification.

(e) Test anomalies were identified in the file; however, there were no BG&E evaluations of the anomalies to see if they agreed with the test labs disposition or what affect the anomalies had on BG&E's actual equip-ment application.

The inspector also reviewed an internal BG&E letter, dated October 3, 1984, that states an FCR is being prepared to replace terminal blocks in instrumentation circuits by qualified splices.

(See discussion in paragraph 4.F.(11)

on IE Information Notice (IN) 84-47).

(11) The inspector's review and evaluation of qualification file C8LO14 for Cerro "FREP/FR" Neoprene cable, TER item 83, identified six areas of concern.

These concerns are:

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(a) Similarity between the installed cable and the tested cable was not adequately addressed in the file.

(b) Acceptance criteria for cable installed in CCNPP were not given.

(c) Qualified life of cable was not adequately addressed.

(d) Effect of accident environment on (aged) cable near end of its qualified life was not addressed.

Radiation aging and LOCA simulation was done on a new cable, not a cable near the end of its qualified life.

No justification or analysis for this was provided in the file.

(e) Qualification was based on a test report identified in the referenced inspection reports of IE IN 84-44 as not having supporting test data to allow the report to be

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audited.

(f) The file was not auditable to the extent that constant

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assistance from the BG&E engineer that had prepared the package was required to evaluate the package.

In

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some instances of question, the engineer had good verbal justification in support of cable qualification; however, he had not documented the justification in the file.

(12) The inspector's review and evaluation of qualification file CBL015 for BIW coaxial cable, TER item 85, identified three questio n concerning the file itself and one technical issue.

When the inspector discussed these items with BG&E, they went back and reviewed other documentation they had and determined that this BIW cable was not used in a 10 CFR 50.49 application and therefore qualification was not necessary.

BG&E was then asked to check their other coaxial cables to determine what cable was used in 10 CFR 50.49 applications in

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CCNPP, Unit 1.

After a review of data, BG&E also deleted Raychem coaxial cables identified under TER items 77 and 78 from the scope of 10 CFR 50.49 requirements.

At the same time BG&E identified Rockbestos coaxial cable, qualification file CBLO31, and Brand-Rex coaxial cable, qualification file CBLO29, as being used in CCNPP, Unit 1, for applications within the scope of 10 CFR 50.49.

The inspector's check of BG&E's 10 CFR

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50.49 list identified the Brand-Rex cable as being on the list;

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however, Rockbestos cable was not on the list.

BG&E attributed this fact to the delay time, previously discussed, for FCRs.

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review of the Rockbestos coaxial cable qualification file is discussed in paragraph 4.D.(16) below.

The Brand-Rex cable file was not reviewed by the inspector.

(13) The inspector's review and evaluation of qualification file

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SV0002 for Dragon solenoid valve, TER item 95, determined that the file was not auditable.

Discussions with BG&E personnel clarified, to some degree, the qualification status and the in plant configuration of the valve, which supposedly had been replaced in April 1982 with a qualified Valcor model V526-5295 per a justification for continued operation (JCO) dated February 26, 1982.

The plant site inspection on October 18, 1984 verified that the Dragon valves were still in place in the west piping penetration room.

Examples of items in the file which led to the determination that the file was not auditable are:

(a) The file contained no QRRS or QEW.

(b) The file contained specifications, drawings and manu-facturers certificate of compliance, but no qualification reports or analysis.

(c) A FCR in the file stated that the Dragon valves were not qualified for their intended use and that oper-ability of these valves could not be established to provide post-accident hydrogen sampling capability.

This FCR had not been closed out (i.e., no verification that the valves had been replaced).

(d) Notation on a current SCEW sheet indicated that the Dragon valves had been replaced.

(e) Records in the file indicated that environmentally qualified Raychem heat shrink sleeves were applied to the valve teflon leads as stated in the referenced JCO.

BG&E now considers these valves qualified based on the application of the sleeves.

BG&E says the sleeves will assure continued valve operability in the event the teflon leads become degraded as a result of a high radiation post-LOCA environment.

(f) The file contained no documentation attesting to the qualified states of these valves nor did the file contain evaluations of the sleeves for the service environment or reference any qualification reports for these sleeves.

BG&E verbally said that they do plan to go ahead and replace the Dragon valves with the Valcor valves due to spare parts unavaila-bility.

This will be done during the next refueling outag j c.

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(14) The inspector's review and evaluation of qualification file SV026

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for Target Rock (TR) solenoid valves identified the following i

areas of concern which BG&E should address in their qualifi-cation file.

(a) The're was no documentation in the file to show that the licensee had assessed the operability requirements of the installed valves.

(b) One test anomaly was documented in TR test report No.

2375, Revision A, dated September 26, 1979; however, BG&E provided no analysis in the file to address the anomaly.

The anomaly was described as intermittent operation of one set of contacts on the valve's relay.

(c) The above TR report also indicated that all valve internal electrical components have exhibited evidence of wetness and some corrosion evident on the lead junction parts.

(The valve was disassemblied and inspected.) The wetness and corrosion was attributed to the failure of the cement sealing compound used to seal the test instrumentation wires at the conduit connection.

The sealing compound had shrivelled and pulled away during test and allowed borated water to enter the inside of the valve enclosure.

BG&E proposed that watertight electrical sealing compound be used at the conduit entrance for TR valves installed at CCNPP, and FCR-81-1001 was issued.

There is no l

indication in the EQ file as to what type of water-tight sealing compouna was installed and there is no EQ documentation in the file to support qualification

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of the compound.

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(d) There was no evidence that the licensee had actually done a walkdown of installed equipment to ensure that all TR valves are installed in accordance with

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the tested valves' configuration and interfaces.

l (15) The inspector's review and evaluation of qualification file SV0014 for ASCO solenoid valves model NP8316A75E identified a number of instances where the data in the file was either conflicting and/or confusing to the point that it was not i

l clear to the inspector as to what was the basis of

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qualification.

Examples of the conflicting and confusing data are:

(a) W91e report 17467-SV0014, dated July 29, 1984,

evaluated the qualification of valve model NP8316A75E; however, the final walkdown verified the model number as NP8316A75V.

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(b) ASCO test report AQR-67368, Revision 0, dated March 2, 1982, (this report is the one evaluated in the Wyle report) ststes that the NP8316A75V valve is only qualified t.o the levels identified in previous ASCO report AQS-21678/TR, Revision A, dated July 1979, only for those applications where valves are not required to shift position following exposure to gamma radiation doses in excess of 20 megarads.

However, SCEW sheet data for the NP8316A75V valve references the March 2, 1982, report and says the valve is qualified to 448'F and 182 megarads, values consistent with the March report and not the earlier July report.

(c) The file also contained Wyle report 17467-SV0028 and referenced qualification file SV0028; however, it was not evident from reviewing the SV0014 file how the ot.her data supported qualification of the NP8316A75V mocei valve.

The SV0028 qualification file applies to ASCO model NP8320A185V valves.

(d) The file did not clearly document what component replacement intervals were required for the valve.

(16) The inspector's review and evaluation of qualification file CBLO31 for Rockbestos coaxial cable determined that qualifi-cation for the cable was based on Rockbestos report #2806 which was one of the reports discussed in the inspection reports referenced in IE IN 84-44.

The inspector did evaluate an internal BG&E letter from S. Parr, dated August 30, 1984,

.concerning the IN; however, sufficient justification to support qualification of the cable, in view of the IN, was not provided.

BG&E personnel verbally told the inspector that they were still looking into the matter and they might be able to qualify the cable based on data from the system qualification test for the

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high range radiation monitoring system (HRRMS).

The cable's only 10 CFR 50.49 application at CCNPP is in the HRRMS, which I

was qualified as a system, including cable.

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Based on the above findings, the NRC inspection team determined that the qualification documentation files reviewed were either

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not auditable or were not adequate and/or accurate enough to l

establish the qualified status of electrical equipment within j

the scope of 10 CFR 50.49.

The NRC will review BG&E's qualification documentation files

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l again during a future inspection to determine the files adequacy and accuracy in establishing the qualified status of electrical equipment within the scope of 10 CFR 50.49 (50-317/84-27-08).

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E.

Use of JCOs During the course of the inspection questions rose concerning the use of JCOs and/or evaluations which justify useage of unqualified 10 CFR 50.49 equipment during plant operation.

Instances when these questions came up were:

1.

Discussions-concerning BG&E's planned actions to replace Marthon terminal blocks with Raychem qualified splices in instrumentation circuits based on evaluations conducted as a result of IE IN 84-47.

2.-

Discussions concerning the fact that limit switches were now going to be included in BG&E's EQ program.

This decision was made by BG&E's "Q" committee this past summer.

3.

Discussions concerning the qualification of Dragon valves as being presently used in the plant today.

Discussions with BG&E focused on whether or not a JC0 is required once BG&E makes a determination that some equipment is not qualified or was not within the scope of 10 CFR 50.49, but now is determined to be within the scope.

In other words, what documentation is required during the time period installed equipment is identified as needing to be replaced or qualified so that BG&E_can continue operation of CCNPP until the installed plant equipment is determined to be fully qualified.

Based on discussions during the inspection and NRR-EQB's representative on the inspection team with a NRC legal representative, the following position was established.

Once the licensee makes a determination that some action needs to be taken to quality a piece of equipment installed in a plant, then he needs to evaluate whether or not he

i should submit a JCO.

If he decides that a JC0 is not needed then he should, as a minimum, maintain documentation and evaluations which describe why a JC0 is not needed and why there is no significant safety hazard in the continued operation of the plant.

In addition to.the above, it is recommended that the documentation include an updated status concerning the actions being taken to bring the installea equipment to a qualified state.

Any evaluations and/or documentation regarding the above should be available for review by the NRC.

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F.

Information Notice The NRC inspector reviewed and evaluated BG&E's activities relative to the review of EQ related IE ins / Bulletins.

The inspector's review and evaluation included examination of BG&E's records relative to 12 ins and one Bulletin.

The inspector's evaluation determined that while procedure CCI-139C requires a plant operating experience assessing committee (POEAC) to review ins, gives the committee chairman the t

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ability to assign required reviews to individual or groups, and requires the committee to review the results, there were no procedural l

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requirements for the individual reviewer or group to provide review results to the committee.

The inspector identified several IN items (see paragraphs 4.F.(2), (7), and (8) for details), which the committee had assigned to individuals and groups for review and where the review results were never provided to the committee for their evaluation.

The NRC inspector recommended to BG&E that they evaluate their system to determine if a closed-loop procedure needs to be established to assure adequate review and evaluation of ins.

(1)

IN 81-20:

Test Failures of Electrical Penetration Assemblies:

The inspector reviewed records that indicated the POEAC had reviewed the content of this IN in its meeting, no. 82-05, and had determined that CCNPP EPAs did not use silicon RTV.

(2)

IN 82-03:

Environmental Tests of Electrical Terminal Blocks:

The inspector reviewed records which indicated the-P0EAC had met and reviewed the IN.

The review resulted in action item 82-047 as identified in the minutes to meeting no. 84-13.

There was no documentation to indicate how this action item was resolved.

BG&E verbally told the inspector that procedure E-406 covers the cleanliness requirements for all equipment at CCNPP and that CCNPP maintenance personnel are bound by the requirements of the procedure.

(3) Bulletin 82-04:

Deficiencies in Primary Containment EPAs:

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l The inspector reviewed records that indicated CCNPP has Bunker Ramo EPAs utilizing hard epoxy modules and that l

they have replaced a number of EPAs (Model 2E Amphenol Sam)

with Conax EPAs on FCR 82-148.

The inspector also identified

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l that CCNPP has other Bunk Ramo EPAs (Models 2A, 28, 2C, 2D, 3A, l

and 3D) but they are not the hard epoxy design.

(4)

IN 82-11:

Potential Inaccuracies in Wide Range Pressure Instruments Used in Westinghouse Designed Plants:

The inspector reviewed records that indicated POEAC had reviewed this IN and have determined that the identified problem is being addressed by their Nuclear Fuel Management and EQ sections along with ITT Barton instrument uncertainties in compliance with Bulletin 79-01B.

(5)

IN 82-52:

Equipment Environmental Qualification Testing Experience:

The inspector reviewed records which indicated the POEAC had reviewed the notice and had identified no problems requiring BG&E action.

This finding is documented in the minutes of meeting no. 83-02.

.

-.

._

o

?

- 19 -

(6)

IN 83-40:

Need to Environmentally Qualify Epoxy Grouts and Sealers:

The inspector reviewed records to indicate that the P0EAC had reviewed this notice.

Minutes of meeting no. 83-13 documented that the IN was sent to the Principal Engineer, Plant Engineering Nuclear, for information.

This issue was assigned to the mechanical representative for further research.

BG&E provided documentation (attachement 13 to minutes of POEAC meeting no.

84-07), to show that fin ~l disposition had been taken to close a

out this action item, 83-13-5d.

(7)

IN 83-45:

EQ Test GE "CK-2940" Switch:

The inspector reviewed records that indicated the POEAC had reviewed this IN and had forwarded it to the Supervisor, Test Equipment for information.

This was documented in the minutes of meeting no. 83-14.

BG&E had no documentation to indicate what the final disposition of this notice was.

(8)

IN 83-72:

EQ Testing Experience:

The inspector reviewed records that indicated the P0EAC had reviewed this notice and referred it to the engineer in charge of the EQ program.

The inspector found no records to show how each item of concern identified in the IN was dispositioned except for ITT Barton transmitters and Limitorque valves.

The inspector examined documentation that indicated a plant walk-down was performed to examine all internal components of the Limitorque valves.

This walkdown identified a number of parts with undetermined status; however, all were corrected or replaced on FCR-83-1014.

The inspector also reviewed data that documented the fact that BG&E had performed the recommended retrofit of Barton transmitters; however, there was no documen-tation to show how BG&E dispositioned the problems with the zero-

,

I base and suppressed-zero model transmitters.

(9) IN 84-23:

Results of NRC-Sponsored Tests on ASCO Solenoid Valves:

The inspector reviewed documentation that indicated CCNPP has two ASCO solenoid valves, model NP-8316 and the POEAC had reviewed the notice.

The P0AEC review was documented in minutes of meeting no. 84-09.

The inspector reviewed a letter dated May 31, 1984, to show how the notice was dispositioned; however, this review determined that the licensee's evaluation did not adequately addreas the staff's concern as was stated in the IN.

!

l l

--

_. _ _ - _. -

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- 20 -

_'(10) IN 84-44:

E0 Testing of Rockbestos Cable:

The inspector reviewed documentation that the POEAC had reviewed the notice and minutes of meeting no. 84-17 documented that no further action was considered necessary.

The inspector also reviewed a QA surveillance audit at the Rockbestos facility in New Haven, Connecticut, on August 2, 1984.

No other records

<

I were found to describe what type of action the licensee will

'take to qualify the Rockbestos/Cerro cables installed at CCNPP, Unit 1 in order to meet the 10 CFR 50.49 deadline.

(See

,

-

discussion in paragraph 4.D.(11) and (16).)

!

(11) IN 84-47:

EQ Tests of Electrical Terminal Blocks:

The inspector reviewed data that indicated the licensee had reviewed the IN.

The action taken by the licensee concerning this IN is to change all instrumentation circuit terminal blocks to qualified splices.

These changes will be performed on all instrumentation circuits that have the potential of being

-

exposed to loss-of-coclant accidents and main-steam-line breaks.

l

,

!

(12) IN 84-57:

Moisture Intrusion in Safety-related Electrical Equipment:

,

l The inspector reviewed documentation that indicated the licensee had reviewed this notice. The inspector's review determined that

,

the licensee feels the concerns raised by the IN have been adequately addressed in the actions performed under FCR-81-1001

,

[

and the activities required to be performed by procedure E-406.

(13) IN 84-68:

Improperly Rated Field Wiring to Solenoid Valves:

The inspector reviewed records that indicated the licensee had reviewed this notice.

The inspector determined that CCNPP has both Valcor and Target Rock solenoid valves.

The inspector

L evaluated the heat rise analysis performed to demonstrate that

the field wires to these solenoids are adequate for their i

required functions and determined that the ambient temperature i

for the post-accident environment had not been incorporated in the analysis.

The inspector discussed this condition with the

BG&E engineer who had performed the valve analysis and recommended l

that BG&E include the above condition in their analysis.

l L

I PERSONS CCNTACTED

'

=pany b]ho r e Gu s mci Floc Yr[,'

cates _ de Tobee IS, /q M Ce,.lveel CI?ff-L)e.'t 2 Scket/ Report No. Id-7/'7/fY-2 '7 __

Inspector

_.

_ _

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Attachment 4 Calvert Cliffs Unit 1 EQ Inspection Report Format The following report format should be used, as appropriate, to document inspector's

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activities during the Calvert Cliffs inspection.

Introduction:

Describe scope of evaluation Identify areas evaluated Identify equipment involved Identify system equipment is part of Identify plant location of equipment

/

Areas of Inspection:

List documents reviewed List names, titles, and organizations of people contacted List plant locations inspectea /

State requirements '

Findings:

State deviations Discussion:

Describe any open items

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Describe what you did Discuss any other coments considered pertinent to the inspection Identify part of inspection module evaluated. Provide Coments:

constructive comments on module and its usage.

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Attachment 4 Calvert Cliffs Unit 1 EQ Inspection Report Format The following report format should be used, as a'ppropriate, to document inspector's activities during the Calvert Cliffs inspection.
Introduction:
Describe scope of evaluation Identify areas evaluated Identify equipment involved Identify system equipment is part of Identify plant location of equipment
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Are6s of Inspection:
List documents reviewed ist names, titles, and organizations of people contacted List plant locations inspectec <
Findings:
State requirements
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State deviations Discussion:
Describe any open items Describe what you did Discuss any other coments considered pertinent to the inspection Identify part of inspection module evaluated.
Provide Cormients:
constructive coments on module and its usage.
Inspector's should feel free to expand their reports beyond the areas Note:
discussed above if they feel it is justified.
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v t e Inspection Report - Calvert Cliffs - 1984027
80 \| 81 \| 82 \| 83 \| 84 \| 85 \| 86 \| 87 \| 88 \| 89 \| 90 \| 91 \| 92 \| 93 \| 94 \| 95 \| 96 \| 97 \| 98 \| 99 00 \| 01 \| 02 \| 03 \| 04 \| 05 \| 06 \| 07 \| 08 \| 09 \| 10 \| 11 \| 12 \| 13 \| 14 \| 15 \| 16 \| 17 \| 18 \| 19 \| 20 \| 21 \| 22 \| 23 \| 24 \| 25 \|
1984 Quarterly Integrated 1Q (0) 2Q (0) 3Q (0) 4Q (0) Assessments Mid Cycle End of Cycle 16(0) 27(0) 99(0) Security Operator Exams Emergency Planning Other

IR 05000317/1984027

Text

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