IR 05000413/1985040

Insp Repts 50-413/85-40 & 50-414/85-38 on 850909-13.No Violation or Deviation Noted.Major Areas Inspected:Matl Identification & control,housekeeping,safety-related Structures & Components & HVAC Sys

ML20138A413
Person / Time
Site:	Catawba
Issue date:	09/24/1985
From:	Blake J, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20138A391	List: IR 05000413/1985040 ML20138A385
References
50-413-85-40, 50-414-85-38, NUDOCS 8510080548
Download: ML20138A413 (9)

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0 UNITED STATES

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Report Nos.: 50-413/85-40 and 50-414/85-38 Licensee: Duke Power Company 422 South Church Street Charlotte, NC 28242 Docket Nos.: 50-413 and 50-414 License Nos.: NPF-35 and CPPR-117 Facility Name: Catawba 1 and 2 Inspection Co u . ember 9-13 85 Inspector: /- - _e- - -

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7d is" WP/ Kleins r Date Signed Approved by: -/ [ 74 W J . J . B)a i Sec' tion Chief Date Signed Engineeri Branch Divis(on f Reactor Safety SUMMARY Scope: This routine, unannounced inspection entailed 41 inspector-hours on site in the areas of housekeeping (548348), material identification and control (429028), material control (429408), safety-related structures - observation of work and work activities (480638)(Unit 2), safety related heating ventilating and air conditioning (HVAC) systems (50100)(Unit 2) and safety-related components (500748)(500768)(Unit 2).

Results: No violations or deviations were identified.

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REPORT DETAILS Persons Contacted Licensee Employees

• J. W. Hampton, Manager, Catawba Nuclear Station

• L. R. Davison, Project QA (Quality Assurance) Manager

• C. A. Robinson, Sr., QA Supervisor - Vendors

• J. W. Baggett, QA Specialist - Vendors

• H. L. Atkins, QA Engineer - Projects

• M. R. Hemphill, QA Engineer - Projects

• W. R. Lovingood, Construction Civil

• E. G. Williams, Project QA Technician Other licensee employees contacted included construction craftsmen, engineers, technicians, and office personne Other Organizations

• C. L. Rice, Jr., Project Manager Bahnson Service Co. (BSC)

• W. M. Crute, Project Engineer BSC

• B. Williams, QA Engineer BSC

• R. Guston, Quality Control (QC) Engineer BSC

• P. J. Rapone, Site Manager Westinghouse (W) ,

NRC Resident Inspectors

• P. K. VanDoorn, Construction

• P. H. Skinner, Operations

• Attended exit interview Exit Interview The inspection scope and findings were summarized on September 13, 1985, with those persons indicated in paragraph 1 above. The inspector described the areas inspected and discussed in detail the inspection findings. No dissenting comments were received from the license (0 pen) Unresolved Item 414/85-38-01: " Qualification of Vendor Auditors" -

paragraph 7a (0 pen) Unresolved Item 414/85-38-02: " Westinghouse Pressurizer / Steam Generator Storage Requirements" - paragraph 8b(1).

The licensee did not identify as proprietary any of the materials provided to or reviewed by the inspector during this inspectio ]

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3. Licensee Action on Previous Enforcement Matters (927018)(927028)

Not inspecte . Unresolved Items Unresolved items are matters about which more infonnation is required to determine whether they are acceptable, or may involve violations or deviations. New unresolved items identified during this inspection are discussed in paragraph 7a and 8b(1).

5. Independent Inspection Effort Housekeeping (548348), Material Identification and Control (429028) and Material Control (429408) (Units 1 and 2)

The inspector conducted a general inspection of the control room, turbine buildings, and the Unit 2 auxiliary building to observe activities such as housekeeping, material identification and control; material control, and storag Within the areas examined, no violations or deviations were identifie . Safety-Related Structures - Observation of Work and Work Activities (48063B)

(Unit 2)

As the window of opportunity had passed to perform direct observation of work in progress, the inspector made a physical examination of the completed containment spray heat exchanger 28 support and reviewed associated records to ascertain whether activities relative to safety-related structures and supports (except welding) outside of containment had been accomplished in accordance with NRC requirements and Safety Analysis Report (SAR)

commitment The following areas were examined: receipt inspection and storage; installation / erection; use of specified materials and components; testing and Nondestructive Examination (NDE); inspection and inspection records; utilization of qualified NDE and inspection (QC) personnel; and calibration and use of proper test equipmen Within the area examined, no violations or deviations were identifie . Safety-Related Heating Ventilating and Air Conditioning (HVAC) Systems (50100)(Unit 2)

Bahnson Service Company (BSC) was contracted by Duke Power Co. (DPC) to fabricate, install, inspect and test the safety-related HVAC system under the BSC program. The inspector reviewed procedures, examined completed work and reviewed relevant QA records to ascertain whether plans, inspections and procedures, technical requirements, work and work activities and relevant QA records related to safety-related HVAC systems were consistent with NRC

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requirements and SAR commitment The applicable codes for the fabrication and installation of the safety-related HVAC systems are:

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American Welding Society (AWS) D1.1-77

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AWS D American Society of Mechanical Engineers Boiler and Pressure Vessel (ASME B&PV)

Code Section IX 1977 Edition

- Sheet Metal and Air Conditioning Contractors National Association (SMACNA) "High Velocity Duet Construction Standard" - 1969 The following areas were examined: Review of Contractor's QA Manual (35100)

The inspector reviewed the QA Manual, implementing procedures, and referenced documents listed below to determine whether adequate QA plans and procedures, including inspection (QC) procedures have been established to assure that the following activities are controlled and accomplished in accordance with QA program requirements: organizational structure and QA personnel; quality requirements; work and inspection procedures; control of materials; control of process; corrective action; dr;ument control; test control and control of test equipment; quality records; and onsite design control Identification Title BSC-QAM No. 56 " Quality Assurance Manual" BSC-QFP-CNS " Quality Field Procedures Manual Catawba Nuclear Station" With regard to the examination above, the inspector noted that the BSC QA program does not require auditors to be qualified in accordance with American National Standards Institute (ANSI) standard ANSI-N45.2-23-1978, " Qualification of Quality Assurance Program Audit Personnel for Nuclear Power Plants." This appears to be contrary to Table 17.0-1 page 3 of 3 of the " Duke Power Company Topical Report, Quality Assurance Program Duke-1A" which indicates that the Duke QA program conforms to ANSI-N45.2.23-197 The licensee indicated that BSC perform their own audits under their program in accordance with ANSI N45-2, and further DPC does not and has not performed BSC audits. The licensee further stated that the topical report does not require DPC vendors to have auditors qualified in accordance with ANSI N45-2, 23-1978, therefore, DPC did not impose the requirements of ANSI N45-2.23-1978 on their vendors. At the time of this inspection it could not be determined whether the DPC interpretation of the topical report is correct, i.e. ANSI-N45-2.23-1978 is not required for DPC vendors or Table 17.0-1 page 3 of 3 requires DPC vendors to comply with

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ANSI-N45-2.23-197 Pending NRC resolution of the above this matter will be identified as unresolved item 414/85-38-01: " Qualification of Vendor QA Auditors".

b. Review of QA Implementing Procedures The inspector reviewed the below listed documents to determine whether:

adequate inspection procedures had been established for HVAC activity; provisions had been made to ensure that those engaged in conducting inspections were qualified and had been adequately trained; means had been established to verify that the technical requirements had been specified in, and were subsequently extracted from, the design and procurement documents and incl _ded in appropriate work and QA inspection procedures; means had been established to verify that any significant design and field changes from approved drawings were adequately controlled and processed commensurate with the original design; provisions had been established to ensure that quality requirements were met; safety-related/nonsafety-related boundaries and equipment were clearly defined and delineate c. Review of Work Procedures The inspector reviewed the below listed procedures to determine:

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Whether procedures and instructions pertaining to the installation of HVAC ductwork, seismic supports, and other safety-related aspects of the installation were reviewed and approved by AE/ licensee personne Whether approved procedures and instructions were appropriate and adequate for proper installation and inspection of the safety-related HVAC system, and whether those controls incorporated the following: controls to ensure that the type and classification of seismic supports for the HVAC ductwork comply with approved drawings and/or specifications; provisions for ensuring that required preinstallation and in-process inspections were performed at the appropriate time for HVAC safety-related equipment; means to ensure that bolts, nuts, and washers (including lubricant, if used) for supports were of the proper type and correctly installed, and where required, bolt preloading (torquing), minimum bolt embedment, and thread engagement criteria were imposed; provisions to ensure the proper location of equipment criteria, dampers, filters, and et Identification Ti tle DPC-Specification " Heating Ventilating and Air CNS-1211.00-00-0005 Conditioning dtd Sept. 1, 1976, Rev. 103 i

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DPC-Specification " Auxiliary Building, Fuel Pool CNS-1211.00-00-0005 Heating Ventilating and Air Supplement No. 5, Conditioning" Rev. 98 DPC-CN/SRD-Design " Design Requirements for Seismically Criteria 77-1.0, Rev. 4 Qualifying HVAC Duct / Hanger" DPC-Specification No " Control. Panel Fabrication Require-CNS-1211.00-00-0005 ments for Nuclear Safety Related Supplement 5 Panel s"  ;

Attachment 4, dtd November 13, 1981 l DPC-Specification " Structural Design Requirements for CNS-1211.00-00-005 Auxiliary Building Ventilation Supplement 5, System" Attachment 6 dtd March 1, 1978 BSC-QFP-CNS " Quality Field Procedures Catawba Nuclear Station" BSC-QAM " Quality Assurance Manual" BSC-QCI-9.001-CNS, Rev. 2 " Visual Weld Inspection" BSC-QCI-9.002-CNS, Rev. 1 " Welder Qualification Log" '

BSC-QCI-9.003-CNS, Rev. 1 " Welder Qualification" BSC-AFP-CNS-11.001, Rev. 5 " Duct Leak Testing Procedure" BSC-AFP-CNS-11.002, Rev. 5 " System Test and Balance Procedure" BSC-AFP-CNS-11.006, Rev. 1 " Water Balance Procedure for HVAC Systems" BSC-QCI-2.001-CNS, Rev. 5 " Training Qualification and Certification of Quality Control Inspection Personnel" BSC-Drawing - 2682-8-20, Rev. 4 DPC-Drawing - CN-2522-06.40-01, Rev.14A BSC-Drawing - CN-2522-06.40-01, Rev 8 ,

DPC-Drawing - 2577-2.0, Rev. 4 DPC-Drawing - CN-1220-43, Rev. 17 DPC-Drawing - 2-H-VF-1204, Rev. 1 DPC-Drawing - 2-H-VF-1407, Rev. 1

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d. Observation of work and work activities (1) Personnel Interviews Personnel interviews could not be accomplished as the work had been completed and; therefore, the window of opportunity has passe (2) Installation Activities The inspector performed a walkdown inspection of the fuel pool exhaust duct FPX--MD-1 from fire damper 2VF-FD-11 to the fuel pool filter unit FPFU-2B2 and reviewed pertinent inspection records to ascertain whether the latest issue (revision) of applicable drawings or procedures were available to the installers and had been used; modifications to supports were approved by appropriate personnel before implementation; anchor bolt type, diameter, embedment length, shoulder-to-cone measurement and torque requirements (where applicable) met installation requirements; QC inspection of welder qualification procedures and welding of safety-related supports was conducte (3) As-Installed Equipment The inspector examined the below listed installed inspected and accepted equipment for proper location, configuration, identifi-cation, and damage. The basis for this determination was the Safety Analysis Report (SAR) system description, piping and instrumentation diagrams (P& ids), specification, and installation drawing Component Identification Fire Damper 2VF-F0-11 Drop Sample Port 2VFPX-5630 Airflow Monitoring Device 2FPX-AFMD-28 Back Draft Damper 2FPX-0-8B Manual Volume Damper 2FPX-MVD-9 Motor Operated Damper 2FPX-D-7B Motor Operated Damper 2FPX-D-58 Manual Volume Damper 2FPX-MVD-10 Support 2HVF-1204, Rev. 1 Support 2HVF-1407, Rev. 1 Connecting Duct Work FPX-2-MD-1 Fuel Pool Filter Unit FPFU-28-2 Instruments 2VFTS-5980 2VFTE-5980 2VFTE-5990 2VFTS-5990

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2VFTH-5450 2VFTH-5460 2VFPS-5450 2VFPS-5480 2VtP-5340 2VFFE-5340 2VFPS-5030 2VFTH-5540 2VFPS-5770 Within the areas examined, no violations or deviations were identifie . Safety-Related Components (Unit 2) i Observation of Work and Work Activities (500748)

The inspector reviewed procedures and records of completed work to ascertain whether activities relative to safety-related components (other than the reactor pressure vessel and piping) had been accomplished in accordance with NRC requirements and SAR connitment Record review was selected, because the window of opportunity to observe active work had passe The inspector selected for review the 2A-steam generator, the pressurizer, the 2A-reactor coolant pump and the 2A safety injection system accumulato The review was made to determine whether the following activities for each of the above components met applicable requirements: storage handling and protection; installation; protection after installation; and nonconforming components or activitie Review of Quality Records (50076B)

The inspector reviewed quality related records relative to safety-related components (other than the reactor pressure vessel and piping),

to ascertain whether these records reflected work accomplishment consistent with NRC requirements and SAR connitment (1) The inspector selected the same components as indicated above for *

review to ascertain whether the records are in conformance with established procedures and whether they reflect work accomplish-ment consistent with applicable requirements in the following areas: storage inspection; installation inspection; material and fabrication certifications / test reports; and nonconformance/

deviation report With regard to the inspection above, during this inspection, the licensee was unable to provide any objective quality evidence (00E) that the storage requirements specified in " Westinghouse fW NSSS Component Receiving and Storage Guidelines", Rev.1, and ,),

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Attachment 120A paragraph 5.1.2 " Receipt Inspection" (purge gage readings) paragraph 5.1.3 Site " Storage" (purge gage readings) and Attachment 1208 paragraph 5.2 " Secondary Side" and paragraph 6.0,

" Surveillance", for the steam generators and the pressurizer. The licensee indicated that they would continue looking for 0QE evidencing the performance of the W storage requirements or contemporaneous records of engineerilig evaluation supporting not performing of the }( storage requirements. Pending NRC review of the above 0QE or engineering evaluation, this matter will be identified as Unresolved Item 414/85-38-02: " Westinghouse Pressurizer / Steam Generator Storage Requirements."

(2) The inspector reviewed the records of the below listed QA audits associated 'with safety-related components to ascertain whether applicable requirements were met in the following areas: records confirm that the audits performed were of the scope and frequency specified; deficiencies identified during the audits were corrected (or are being corrected in a timely manner) and documented; corrective action was such that repetition of the deficiency, or similar deficiencies, would be precluded; auditors were qualified for the work they performe Audits l

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DepartmentalAuditCD-84-11(CN)

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Departmental Audit CD-84-17(CN)

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i Within the areas examined, no violations or deviations were identifie [

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