IR 05000483/1987010

Insp Rept 50-483/87-10 on 870405-0531.No Violations Noted. Major Areas Inspected:Operational Safety,Esf Sys Walkdown, Maint,Surveillance,Radiological Control,Fire Protection, Security,Emergency Preparedness,Outages & Quality Programs

ML20215H810
Person / Time
Site:	Callaway
Issue date:	06/18/1987
From:	Hinds J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20215H791	List: IR 05000483/1987010 ML20215H789
References
50-483-87-10, NUDOCS 8706240221
Download: ML20215H810 (11)

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U. S. NUCLEAR REGULATORY COMMISSION

REGION III

Report No' 50-483/87010(DRP)

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Dockst No. 50-483 License No. NPF-30

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Licensee: Union Electric Company .

Post Office Box 149 - Mail Code 400 St. Louis, MO 63166 Facility Name: Callaway Plant, Unit 1 Inspection At: Callaway Site, Steedman, M0 Inspection Conducted: April 5 through May 31, 1987 Inspectors: B. H. Little C. H. Brown

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Approved By J . inds, tin. hief b.i8 67

• eactor Projects ection 1A Date l

Inspection Summary Inspection on April'5 through May 31, 1987 (Report No. 50-483/87010(DRP))

Areas Inspected: A routine, unannounced safety inspection by the resident inspectors of operational safety, ESF system walkdown, maintenance, surveillance, radiological control, fire protection, security, emergency preparedness, outages,. quality programs, and training and qualification ;

effectivenes Results: No violations or deviations were identified in this inspectio '

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DETAILS 1. ' Persons Contacted D. F. Schnell, Vice President, Nuclear'

• G. L. Randolph, General Manager,' Nuclear Operations

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• J. D. Blosser, Manager,-Callaway Plant

• C. D. Naslund, Manager, Operations Support A. P. Neuhalfen, Manager, Quality Assurance

• J. R. Peevy, Assistant Manager, Technical Services P. T. Appleby, Assistant Manager, Support Services M. E. Taylor, Superintendent, Operations D. E. Young, Superintendent, Maintenance

• W. R. Robinson, Superintendent, I&C R. R. Roselius, Superintendent,. Health Physics V. J. Shanks, Superintendent, Chemistry J. A.' Ridgel, Superintendent, Radwaste

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G. J. Czeschin, Superintendent, Planning & Scheduling W. H. Sheppard, Superintendent, Outages J. M. Price, Superintendent, Training G. R. Pendegraff, Superintendent, Security J..E. Davis, Superintendent, Compliance

• D. W. Capone, Manager, Nuclear Engineering T. H. McFarland, Superintendent, Design Control R. D. Affolter, Superintendent, Systems Engineering J. V. Laux, Superintendent, Technical Support

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G. A. Hughes, Supervisor, Independent Safety Engineer Group

'*J. C. Gerhart, Superintendent, QA Operations Support

• T. P. Sharkey, Supervisor, Compliance

• B. K. Stanfield, Quality Assurance Engineer

• J. W. Knaup, Compliance Engineer

• D. Seets, Quality Assurance Engineer

• L. H. Kanuckel, Supervisor, QAPS Engineer j * Denotes those present at one or more exit interview *

In addition, a number of equipment operators, reactor operators, senior reactor operators, and other members of the quality control, operations, maintenance, health physics, and engineering staffs were contacte . Plant Operations Operational Safety Verification (71707)

I Inspections were routinely performed to ensure that the licensee conducts activities at the facility safely and in conformance with regulatory requirements. The inspections focused on the implementation and overall effectiveness of licensee's control of operating activities, and the performance of licensed and nonlicensed operators and shift technical advisors. The following items were considered during these inspection j

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Adequacy of plant staffing and supervisio *

Control room professionalism including procedure adherence, operator attentiveness and response to alarms, events, and off normal condition Operability of selected safety-related systems including

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attendant alarms, instrumentation, and control Maintenance of quality records and report The inspections included direct observation of activities, tours of the facility, interviews and discussions with licensee personnel, independent verification of safety system status and limiting conditions for operation (LC0), and review of facility procedures, records, and report Off-Shift Inspection of Control Rooms The inspectors performed routine inspections of the control room during off-shift and weekend periods, these included inspections during the hours of midnight and 4:00 a.m. The inspections were conducted to~ assess overall crew performance and specifically control room operator attentiveness during night shifts. The inspectors also reviewed licensee's administrative controls regarding " Conduct of Operations" and interviewed licensee's security personnel, shift supervisors and operators to determine if shift personnel were notified of inspector's arrival on site during off-shift The inspectors determined that both licensed and non-licensed operators were attentive to their duties, and that the inspector's arrival on site'was unannounced. The licensee has implemented appropriate administrative controls relating to the conduct of operations. These include procedures which specify fitness for duty and operator attentiveness. Personal radios and reading l materials are prohibited, b. ESF System Walkdown (71710) j The operability of selected engineered safety features (ESF) was l confirmed by the inspectors during a walkdown of the accessible {

portions of the system. The following items were included:

procedures match the plant drawings, equipment conditions, housekeeping, instrumentation, valve and electrical breaker !

lineup status (per procedure checklist); locks, tags, jumpers, '

etc. are properly attached and identifiable. The following systems were walked down during this inspection period:

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"A" Emergency Diesel Generator

"B" Emergency Diesel Generator Essential Service Water System

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ECCS - Subsystems Residual Heat Removal (RHR)

Safety Injection (SI)

Centrifugal Charging Pump (CCP)

Off-Site Power - Shutdown No violations or deviations were identifie . Radiological Controls (71709)

Licensee's radiological controls and practices were routinely observed by the inspectors during plant tours and during the inspection of selected work activities. The inspection included direct observations of Health Physics (HP) activities relating to; radiological surveys and monitoring, maintenance of radiological control signs and barriers, contamination, and radioactive waste controls. The inspection also included a routine review of licensee's radiological and water chemistry control records and report The inspectors performed frequent plant tours during the maintenance outage to assess the effectiveness of licensee's Health Physics (HP)

program implementation relating to occupational radiation safety. The inspectors observed that additional HP staffing was provided for the increase in work activities. HP supervision attended work planning meetings, provided ALARA review and special training. The licensee closely monitored personnel contamination incidents. Licensee's investigation into the cause of hand contaminations found that the decontaminated protective gloves contained residual low levels of radioactive particles. The problem was corrected through a change in the decontamination process and requiring the use of surgical glove liner The inspectors observed that HP controls and practices, implemented by the licensee, were very effective. With only isolated exceptions, excellent HP housekeeping conditions were maintained throughout the outage. Deficient HP conditions or practices noted by the inspectors included; the use of radiological control rope for purposes other than barriers, and used protective gloves and caps were left on valve stems and the floor in the reactor building vice contaminated storage containers. The deficiencies were promptly corrected by HP supervisio No violations or deviations were identifie . Maintenance Selected portions of the plant maintenance activities on safety-related systems and components were observed or reviewed to ascertain that the activities were performed in accordance with approved procedures, regulatory guides, industry codes and standards, and that the performance of the activities conformed to the Technical Specifications. The inspection included activities associated with preventive or corrective

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maintenance of electrical, instrumentation and control, mechanical equipment, and systems. The following items were considered during these inspections: the limiting conditions for operation were met while components or systems were removed from service; approvals were obtained prior to initiating the work; activities were accomplished using approved procedures and were inspected as applicable; functional testing and/or calibration was performed prior to returning the components or systems to service; parts and materials that were used were properly certified; and appropriate fire prevention, radiological, and housekeeping conditions were maintaine The inspectors observed / reviewed the following work activitie Work Request N Activity WR 65595 Terminate Drywell Pressure Indicator WR 413687 Exciter Control Cubicle ARK Breaker MTE-ZZ-QS001 ARK Breaker Parts Replacement MPE-ZZ-QS002 Preventive Maintenance 480 V Electrical Breakers WR 52259 Diesel Generator "A" Starting Air Strainers (CMP 84-117)

PM-P0041253 Valve Inspection and Lubrication (EJ-HV-8716A)

PM-P004392 (40203) Insulation Resistance Test Valve EJ-HV-8840 Valve EJ-HV-8701A WR W101308 NB0104 Feeder Breaker DP-BG-05A Replace position SW operator assembly and guide WR 65094A Corrective Maintenance "Re-Test"

"A" Emergency Diesel Generator No violations or deviations were identifie . Surveillance (61726)

An inspection of inservice, and testing activities was performed to ascertain that the activities were accomplished in accordance with applicable regulatory guides, industry codes and standards, and in conformance with regulatory requirement Items which were considered during the inspection included whether adequate procedures were used to perform the testing, test instrumentation was calibrated, test results conformed with Technical Specifications and procedural requirements, and that tests were performed within the required time limits. The inspector determined

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that the test results were reviewed by someone other than the personnel involved with the performance of the test, and that any deficiencies identified during the testing were reviewed and resolved by appropriate management personne The inspectors observed / reviewed the following activitie Surveillance / Test Procedure N Activity OSP-AC-00005 Main Turbine Overspeed Trip OSP-SE-00003 CalculatetheQuadranI ESP-ZZ-00010 At Power Moderator Temperature Coefficient Measurement MTE-ZZ-QA001 Motor Operated Valve Test (AL-HV-7A)-

ITG-ZZ-E1001 Diesel Generator Bearing Alarm Calibration OSP-SM-LLOL3 Interlock and Leakrate Verification of Emergency Personnel Hatch OSP-SA-00004 Containment Inspection No violations or deviations were identifie . Fire Protection (64704)

Implementation of the licensee's fire protection / prevention program was routinely assessed by the inspectors during plant tours. The inspection included observation of housekeeping conditions, storage and control of combustible material, operability of fire protection / suppression systems, and fire brigade staffing and trainin The housekeeping and control of combustible materials and flammable liquids were found to be satisfactory. The operability of fire protection / suppression systems was found to be maintaine Surve111ances were being performed in a timely manner with the exception of four (4)

valves associated with one of the fire water pumps. This item is being evaluated in Inspection Report No. 483/87018, a routine fire protection inspectio Several fire brigade drills were observed during the inspection interva These were training drills and the instruction appeared satisfactor The brigade members were given direction as they appeared to need further instruction. The manual fire fighting equipment has been maintained in good working order and no deficiencies were reporte No violations or deviations were identifie l

. Emergency Preparedness (82301)

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An inspection of emergency preparedness activities was performed to assess the licensee's implementation of the emergency plan and imple-menting procedures. The inspection included monthly observation of emergency facilities and equipment, observation of licensee performance 3 during training exercises, interviews with licensee staff, and a review ;

of selected emergency implementing procedure '

The inspectors observed portions of two practice Emergency Preparedness Drill In general the participants followed the necessary procedures !

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and performed satisfactorily during the drills. A few minor problems were noted in the communications to the inspector during the later dril The E0F and TSC equipment was noted to be in satisfactory condition on routine walk throug The routine surveillances on the communications were performed in a timely manne No violations or deviations were identifie . Security (71881)

Licensee's security activities were observed by the inspectors during routine facility tours and during the inspector's site arrival and departur Observations included security personnel's performance associated with access control, security checks, and surveillance activities, and focused on the adequacy of security staffing, security response (compensatory measures), and security staffs attentiveness and thoroughnes Security personnel performed security checks and inspections in a thorough and professional manner. The inspectors observed that the security staff performed thorough vehicle inspections of both vendor and utility vehicles entering and leaving the protected area. The security staff was attentive to duties and appeared well trained and responsive in applying compensatory measures and during security drill On one occasion on entering the Central Alarm Station (CAS), the inspector heard the security watch acknowledge " Company's coming" on the phone when advised of the inspectors visit. The inspector noted that the CAS security post was properly manned and the watch was 3 attentive to their duties prior to CAS being advised of the inspector's ;

entr This matter was discussed with licensee's security managemen The inspector was advised that " notification" of inspectors whereabouts j was neither policy or procedure and that security personnel would be instructed in this matter during security staff meeting i No violations or deviations were identifie !

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. Outages (71707)

The inspectors observed or reviewed licensee and contractor activities associated with plant outages. The inspection focused on outage management program implementation; including planning, scheduling, and oversight. activities. The inspection included routine attendance of planning and scheduling meetings, direct observation.of selected modifications, repair or testing of safety systems or components, and the review of quality record The management involvement was observed to be effective. The planning and scheduling resulted in an outage completion in near the scheduled time although several unanticipated items arose during.the outage. The integrated leak rate test (ILRT) was successfully performed. A large ,

number of primary valves were repacked for plant reliability. The management oversight was observed to maintain effective communications between the work groups. The oversight maintained ALARA program less than expected except for unexpected work er one of the steam generator The observation of work in progress inclu%d these design change CMP 84-05-30 - Deletion of Chlorine Monitors From ESFAS CMP 85-0356 - A/C Unit Addition to Rod D' rive MG Set Room CMP 85-0296 - Additional Platform to Diesel Generator Building CMP 85-0479 - Add Cooling Coils to Area 5 HVAC Coil (MSIV area)

The work packages were not completed for review by the close of the inspectio j No violations or deviations were identifie . Quality Programs and Administrative Controls Affecting Quality (35701)

An inspection of licensee's quality programs was performed to assess the implementation and effectiveness of progrems asscciated with management control, verification, and oversight activities. The inspectors considered areas indicative of overall management involvement in quality matters, including the frequency of management plant tours and control J room observations, management personnel's attendance at technical, planning / schedule, and committee meetings. The inspectors attended onsite review committee meetings, incident / event critiques and reviewed related documents, focusing on licensee's root cause determination and corrective action. The inspectors accompanied licensee management on i plant tours monthly which focused on quality activities and material conditions within the plant. The inspection also included the review of quality records and selected quality assurance audit and surveillance activitie <

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Followup on Regional Requests (92701)

< Information Notice Regarding Unqualified AMP Splices: IE Information Notice (IN) No.86-104, alerted licensees of. unqualified butt splice conr.ectors identified in qualified penetrations. An inspection was performed to assess licensee's evaluation and response in this. matter, and to determine if AMP sp1!ces or terminal lugs were used in other equipment qualification applications at the Callaway Plant. The inspection included interviews with licensee engineering and quality assurance personnel, the review of quality records, and an in-plant inspection of Motor Control Centers. The inspector determined the following:

Splices installed in penetrations at Callaway are Amphenol Triax Plug No. 53175-1053 and Jack No.- 52975-1051. These splices are covered by Ray Chem Heat Shrinkable Tubing (HST) which has been qualified by testin *

AMP terminal lugs are specified in three purchase specification However, (KULKA JJthese Seriesare terminated 601, on "q)ualified" 602, and 604 terminal which preclude blocks contact with adjacent wire or the enclosur In' addition, Thomas and Betts Terminal Lugs are installed in auxiliary relay racks in the auxiliary building; however, the application has been qualified by testin Breaker cubical NG01BKF2 contained a Thomas and Betts splice installed by the vendor. There was no equipment qualification documentation for the installed splice. QA documented this-deficiency on a Request For Corrective Action (RCA) No. RP 87-04 The RCA was issued with no response required, based on the licensee's action to remove the MCCs from the equipment qualifi-cation EQ CN listing)in No. 87-4 . the FSAR (Equipment Qualification Change Notice Instrumentation applications use Burndy splices covered by qualified Ray Chem heat shrinkable tubin The inspector findings were discussed with an inspection specialist, Region III, and were found acceptable. This matter is considered close Licensee Action on Previous Inspection Findings (92701)

(Closed) Unresolved Item (483/86007-02(DRP)): On March 11, 1986, the licensee Compliance Department determined that the NRC had not been notified of the Environmental Qualification (EQ) deficiencies documented on Incident Report Nos. 86039 and 86055 within 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> as required by License NPF-30, Condition 2.F. License Condition 2.F. states, "With the exception of 2.C(2) Union Electric shall report any violations of the requirements contained in Section 2.C, of this license within 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />."

Subsequently, based on a more conservative evaluation of reportability, the licensee made a notification of the even *

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The inspector discussed the reporting requirements established by License Condition 2.F. with NRC Region III and NRR staff to determine if the 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> reporting requirements was intended to apply to specific violations, programmatic violations, or both. Based on the discussion, the inspector determined that License Condition 2.F. was provided to assure NRC notification of the licensee's EQ program implementation prior to November 30, 1985, which was satisfactorily performed. The licensee's failure to make a 24-hour report on the above EQ deficiencies is not considered a violation of License Condition 2.F. This matter is considered close (Closed) Unresolved Item (483/86010-01(DRP)): Environmental Qualifica-tion (EQ) of Limitorque Motor Valve Operator Wiring. This item resulted from an inspection which was performed to ascertain the EQ of wiring used in Limitorque Motor Valve Operators. The inspection was in response to Temporary Instruction (TI) 2515/75, (Inspection of Limitorque Motor Valve Operator Wiring) and included a review of licensee's action relative to IE Information Notice (IN) No. 86-03, (Potential Deficiencies In Environmental Qualification of Limitorque Motor Valve Operator Wiring).

The licensee, through the review of quality records and field inspections, identified three valve operators having wiring of questionable EQ statu The licensee replaced the operator wiring associated with these valves (EJ-HV-8716A, B, and EJ-HV-88098) with environmentally qualified wirin The inspector determined that the licensee was responsive to IE Information Notice No. 86-03 and took prompt corrective action to ensure that the installed operator wiring was environmentally qualifie The NRC has determined that no enforcement action will be taken for environmental qualification violations involving unqualified valve motor internal wiring. This decision is based on the generic nature of the deficiencies, extenuating circumstances, and limited potential safety significance of the violation Unresolved Item 483/86010-01(DRP), TI 2515/75, and IN No. 86-03 are considered close No violations or deviations were identifie . Training and Qualification Effectiveness (41400)

A performance evaluation of licensee staff and contractors was performed I to assess the effectiveness of licensee's training and qualification l program. The following items were considered:

Program implementation (various work groups)

Understanding of work i Event and problem causal factors ,

Experience feedback i

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The inspection included personnel interviews, direct observation of training, operation, maintenance, and testing activities, incident / event response and the . review of quality records and report The_ inspector concluded that the performance and response by licensee personnel demonstrated very effective training and qualfication program No violations or deviations were identifie . ExitMeeting(30703)

The inspector met with licensee representatives (denoted under Persons Contacted) at intervals during the inspection period. The inspector -

summarized the. scope and findings of the inspection. The licensee-representative acknowledged the findings as reported herein' . The inspector also discussed the likely informational content of the inspection report with regard to documents or processes reviewed by the inspector during the-inspection. The licensee did not identify any such documents / processes as proprietar l t

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