IR 05000483/1981014
| ML20009G867 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 07/20/1981 |
| From: | Richard Lee, Love R, Williams C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20009G864 | List: |
| References | |
| 50-483-81-14, NUDOCS 8108050161 | |
| Download: ML20009G867 (6) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-483/81-14
~ License No. CPPR-139 Docket No. 50-483 Licensee: Union Electric Company P. O. Box 149 St. Louis, MO 63166 Facility Name: Callaway, Unit 1 Inspected At: Callaway Site, Callaway County, M0 Inspection Conducted: June 16-19, 1981
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Inspectors:
R. S. Love
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R. L. Le
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?'h/hw Approved by:
.'. Williams, Chief
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Plant Systems Section Inspection Summary Insoection on June 16-19, 1981 (Report No. 50-483/81-14)
Area Inspected: Observation of electrical cable / wire installation and termination activities; review of nonconformance, inspection and test reports; review of work and inspection procedures. This inspection involved a total of 53 inspector-hours onsite by two NRC inspectors.
Results: Of the areas inspect'ed, three apparent items of noncompliance (Criterion XVI - failure to identify and control nonccaforming items -
Paragraph 1.c; Criterion X - failure to perform adequate inspections -
Paragraph 3.b; Criterion V - fGlure to follow approved procedures -
Paragraph 3.a) were identified.
8108050161 810723 PDR ADOCK 05000483 O
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DETAILS
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Persons Contacted Union Electric Company
- W.
Stahl, Test Program Coordinator
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- R. Veatch, QA Asst. Engr.
- W. H. Weber, Mgr. - Nuclear Construction Daniel Interational
- A.
D. Arno?.3, Proj. Qvality Mgr.
- M. K. Smith, Audit Response Coordinator
- H. J. Starr, Froj. Mgr.
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- D. 5 ites, Pro;.-QC Mgr.
- W.
L. Sykora, Anst. Proj. Mgr.
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Delcon
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- D.
Hunt, Gen. Elect. Supt.
- D. Schwartz, Ld. Atca Elect. Engr.
- J. Weaver, Manager The_ inspectors also contacted and interviewed other licensee and contractor personnel during this reporting period.
- Denotes those present at the exit interview.
Functional or Program' Areas Inspected 1.
Observation of Electrical Work Activities a.
The RIII inspectors observed the licensee's method for temporarily supporting cable and cable coils of pulled or partially pulled Class 1E cables. The inspectors observed the following:
(1) Sixteen coi.'.ed Class 1E cables ajacent to Panel-No. RL019/RLO20 in the Main Control Room were improperly suppe,rted in that their combi,ned weight was supported by cable number 4EJI11GB.
Other cables identified were numbers:
4SHIO1FA 4EFIO9PA
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4EFI11FB 4EJI11GC 4GSIO8AA 4EGI19BA 4SHIO1GA 4EJI11GA 4EGI11BB 4EJI11GD 4EGI14BA 4SHIO1GB 4EFI11DB 4GNIO5LA 4SHIO1FB
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(2) The licensee's contractor QC and Engineering personnel reviewed the improperly supported cables.
Immediate
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action was taken to properly support the above listed cables as well as other coiled cables in the control room.
(3) Electrical QC inspectors were interviewed in the control room and they stated that it was common practice for the craft " terminators" to cut / remove the coiled cable support ropes and not replace them.
In support of this statement, it appeared that the support rope for the coiled cables identified in Paragraph 1.a(1) had been cut.
(4) DR number 2SD-3768-E, dated June 17, 1981, was prepared to document the improperly supported cables identified by the RIII inspectors. The DR identified minor jacket deformations nn cable number 4EJI11GB.
This is an item of concern and the temporary support of pulled or partially pulled cables will be reviewed on subsequent inspections.
b.
The RIII inspectors observed approaimately 600 completed Class IE cable / wire terminations in the control room panels, 4160V switch-gears No. NB01-05 and No. NB01-10, and in 480V Motor Con:rol Center No. NG01A-HF3. Cable scheme numbers INGB10SB and 1NBB02AC were randomly selected for a follow-up review of QC termination in-spection records and verification of the actual termination landing points as compared with the computer printout.
No items of noncompliance were identified.
c.
The RIII inspectors observed the completed vendor and site con-tractor Class 1E cable / wire terminations and cable supports in Battery Charger No. 2NK21/341 which had been turned over to Union Electric for test.
Lt was observed that on Terminal Block No. 5, Terminal 8, wire No. INK 21-1 was improperly terminated in that only the edge of terminal lug had been placed under the terminal screw. As of June 17, 1981, there was a blue " turn-over" tag attached to the subject wire, which leads the inspe ors to believe that this wire had been de-terminated and re-terminated by the Union Electric Test Group.
T.s item is directly related to Unresolved Item 50-483/81-09-01, which addresses the Quality Control inspection requirements during construction completion and pre-operational testing.
The RIII inspectors informed the licensee that failure to promptly identify and correct the above noncoinforming condition in accordance with QA program provisions is an item of noncompliance, contrary to the requirements of Criterion XVI of 10 C17 50, Appendix B.
(50-483/8'.-14-01)
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d.
The RIII inspectors observed the in process installation of cable scheme number IGKG02AE. The "s'et-up" for this cable pull was in the lower cable-spread-room. The inspectors interviewed the Level II and Level I inspectors providing quality control coverage of the subject pull.
(1) They had the required check lists and work acsignments on hand.
(2) They were able to describe the general routing without referring to the list of (
vias (raceway sections).
(3) They appeared to have a good working knowledge of the inspection criteria.
No items of noncompliance were identified.
2.
Review of Implementing Procedures - Cable Pull The RIII inspectors compared Daniel Int.ernational's procedures WP-302,
" Installation of Electrical Raceway" and WP-303, " Installation of Wire and Cable" with the requirements of Bechtel drawing number E-01013(Q),
Revision 5, and it appears that:
a.
The minimum cable bend radius, as stated in E-01013(Q), could be exceeded if minimum radius conduit bends are made, as permitted in WP-302.
b.
Maximum cable sidewall pressure, as stated in E-01013(Q), could be exceeded during cable pulling if four 90 degree conduit bends are utilized, as permitted in WP-303.
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This is an unresolved item pending review of (1) conduit size requirements es cable size, and (2) cable pulling tension calculations.
(50-483/81-14-02)
3.
Review of Inspection and Test Records - Electrical a.
The RIII inspectors reviewed approximately 100 " Cable Test Records,"
(1-10. cables per sheet), relative to the insulation resistance and continuity testr, performed on electrical cables prior to termina-tion by the licen ee's electrical contractor. The test records reviewed were for one system and were performed between October 4,
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1980 and May 20, 1981.
It was observed that only 11 Test Record sheet indicated that the tests had been witnessed by a Quality Control inspector. Consent for the continuation of work beyond the designated " hold point" (Ref. WP-304, Paragraph 4.1.6) was not documented for the tests not witnessed by Quality Control.
The inspectors informed the licensee that failure to accomplish activities affecting quality in accordance with prescribed QA program procedures is an item of noncompliance, contrary to the requirements of Criterion V, of 10 CFR 50, Appendix B.
(50-483/
81-14-03)
b.
The RIII inspectors reviewed the Quality Control inspection records relative to the inspections performed on the. vias.(section of raceway)
for cable scheme number 1GKG02AE (ref. Paragraph 1.d of this report).
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(1) There were 39 vias involved /ith the cable pulling efforts for the subject cable. There was documented evidence that 38 of the vias had been inspected and accepted. As of
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June 18, 1981, there was no documentation indicating that l
cable tray riser number IC8K54 had been inspected.
(2) The " Cable Installation Checklist" for a given cable scheme
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number indicated that during the pre pull inspection, the-Quality Control inspector verifies and documents that:
(a)
tray sections before initial cable pulling are free of material defects defined as burrs, sharp edges, galvanize chipping or stripping, or anything de';ri-mental to the cable during pulling, and tray sections are aligned so as not to expose any sharp edges at the splice;
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(b) bushings have been insta a on the conduit end; (c) no contamination is visible when it is possible to
see completely through the conduit and where it is impc,=sible to cee through the conduit, a swab or mandrel shall be pulled through the conduit; (d) the raceway is identified at both ends.
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Cable tray riser number IJ1K27 was selected at random for a review of documentation.
It was observed that 16 safety related cables had been installed in the subject tray. As of June 18, 1981, there was no documentation indicating that cable tray riser number 1J1K27 had been inspected.
Paragraph 3.31 of WP-303, Revision 5, states, in part, " Raceways may have cables installed in them even though they have not been completed.
Incomplete raceways, as a minimum, must be marked and properly supported."
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The RIII inspectors informed the licensee that failure to execute the inspection program to verify conformance with the documented instructions, procedures, and drawings for accomplishing
'te activity is an item of noncompliance, ontrary to the requirements of Criterion X of 10 CFR 50, Appendix B.
(50-483/81-14-04)
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Review of Nonconformance Reports - Electrical The RIII inspectors reviewed nonconformance report number 2SN-2148-E and it was observed that per the description noted in the nonconformance report, cable trays IC8K50, IJ1K30, IC8K52 and 1J1K34 were installed even though they had been placed on " HOLD" by the AE.
It could not be determined during this inspection if the subject trays had been i
installed before or after being placed in a " HOLD" status or if they had been installed after the AE's " HOLD" had been removed.
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This item is unresolved and will be reviewed or subsequent inspection.
(50-483/81-14-05)
Unresolved Items Unresolved items are mat. ors about which more information is required in order to ascertain whether they are acceptable items, or items of noncompliance.
Unresolved items disclosed during this inspection are discussed in Paragraphs 2 and 4 of this report.
Exit Interview l
The inspectors met with licensee representatives at the conclusion of the inspection. The inspectors summarized the scope and findings of the inspec-tion. The licensee acknowledged the findings as reported and stated that a
"Stop Work Order" v+:1d be issued on safety related cable pulling pending review of documentation and/or procedure revision.
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