IR 05000483/1987012
| ML20214J327 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 05/18/1987 |
| From: | Jablowski F, Vandel T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20214J315 | List: |
| References | |
| 50-483-87-12, NUDOCS 8705280011 | |
| Download: ML20214J327 (11) | |
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U. S. NUCLEAR REGULATORY COMMISSION
REGION III
Report No. 50-483/87012(DRS)
Docket No. 50-483 License No. NPF-25 Licensee: The Union Electric Company Post Offic.e Box 149 St. Louis, M0 63166 Facility Name:
Callaway, Unit 1 Inspection At:
Callaway Site, Callaway County, Missouri Inspection Conducted:
April 6-16., 1987 G$bMb G
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Inspector:
T. 1.
ndel g./g c' 7 o
Date
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Approved By:
F.
. J b onski, Cnief 5-/P 8 7 Quality Assurance Programs Date Section Inspection Summary Inspection on April 6-16, 1987 (Report No. 50-483/87012(DRS))
Areas Inspected:
An unannounced safety inspection by a regional inspector of:
previously identified concerns; licensee verification and assessment activities of design changes; maintenance program activities; corrective action program; and program change control.
The inspection was conducted in accordance with Inspection Procedures 35701, 37702, 62700, 62702, 92701, and 92720.
Results:
No violations or deviations were identified, however, one unresolved item was identified.
8705280011 870518 PDH ADOCK 05000483 G
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DETAILS 1.
Persons Contacted
- J. D. Blosser, Manager, Callaway Plant D. W. Capone, Manager, Nuclear Engineering
- J. J. Cassmeyer, Assistant Engineer, Program Support QA
- J. C. Gearhart, Superintendent, 0perations Support QA
'*L. H. Kanuckel, Supervising Engineer, Program Support QA
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- J. V. Laux, Superintendent, Technical Support QA-
- T. H. McFarland, Superintendent, Design Control:
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- J. E. McLaughlin III, Superintendent, Administration Records A. P. Neuhalfen, Manager, Quality Assurance G. L. Randolph, General Manager, Nuclear Operations
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- M. A. Reidmeyer, Engineer, Operations QA
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- C. E. Slizewski, Supervising Engineer, Technical Support QA
- J. A. Tunink, Senior Planning, Supervisor
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- B. L. Walton, Assistant Superintendent, Administration Records
- Denotes those attending the exit meeting on April 16, 1987. Other
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personnel were contacted during the course of the inspection.
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2.
Licensee Action on Previous Inspection Findings (Closed) Open Item (483/85013-01):
Three procedures concerning planning guides, Q-Lists, and computer program requirements were incomplete including the following:
I a.
Procedure QAP-ZZ-01830, " Quality Assurance Planning Guide", was-issued with the administrative system number.GDP-ZZ-10830.
This procedure is a series of functionally arranged planning guides to be used as a planning source documer.t for acceptance criteria, requirements and commitments.
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b.
Procedure WEP-ZZ-00011, " Classification of Parts", was issued
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as APA-ZZ-00430.
This procedure, together with Procedure
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APA-ZZ-00018, " Upgrade of Parts, Materials, and Supplies",~provides the controls that assure replacement parts, components and subsystems used in safety related, special scope,fied and/oror non-safety related parent components are appropriately quali upgraded.
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c.
Procedure QE-343, " Classification of Systems and Components", has been replaced by a new Procedure APA-ZZ-00303, " Classification of Systems and Equipment".
This procedure was scheduled for onsite review committee review and approval recommendation on Friday, April 17, 1987.
This procedure established the re methods for determining equipment classification. quirements and
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It also provided a
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the Callaway Equipment Q-List, as a sublist of the master equipment list in the ADABASE computer program being developed.
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Items a - c satisfied the original concerns of the Open Item; therefore, the item is closed.
The inspector reviewed the current Q-List system relied on for the Callaway site.
The following information was. verified.
d.
A four volume set of the SNUPPS Q-List, current to the last revision issued by SNUPPS in 1986, continued to be the basis for evaluation of Callaway partc and components.
This Q-List was the one developed by the architect engineer for classifying systems and components during the design and construction.
Continued maintenance and
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reporting of this list was uncertain.
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e.
In a letter to the NRC dated November 8, 1983, UNLNRC-687, the licensee
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committed to developing a Callaway,Q-List, embodying the SNUPPS Q-List,
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-for use in assigning quality classifications to spare and replacement parts, along with components, f.
In the same letter, the licensee also committed to an onsite
Computerized History and Maintenance Planning Systems (CHAMPS)
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that incorporated design information pertaining to the safety classification of systems and components, and included results i
of the Q-List developement.
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The Superintendent of Design Control informed the inspector that Callaway has substituted the ADABASE computer system for CHAMPS.
The ADABASE master equipment list system, commenced during the testing phase of the plant, was under development.
The Callaway
site Q-List information will be incorporated into the ADABASE master list system.
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The inspector was also informed that the system was expected to be in place and in use by the end of 1987.
The items described in d - h are open for further review (483/37012-01).
No violations were identified.
3.
Quality Assurance Program (35701)
This inspection was conducted to ascertain whether the licensee was implementing a QA, program in conformance with regulatory requirements, commitments, and industry guides and standards. -Management involvement and information flow for management assessment were reviewed.
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a.
Reference Documents (1) Operating Quality Assurance Manual (0QAM), Revision 9.
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(2) Callaway Administrative Procedures.
GDP-ZZ-00106, " Reference Tracking System, Its uses
and Controls," Revision 1.
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GDP-ZZ-00230, " Training, Qualification and Certification
of Quality' Assurance Personnel," Revision 0.
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GDP-ZZ-00600, " Preparation, Review, and Approval,of Revisions and Change Notices to the 0QAM,"
Revision 0.
GDP-ZZ-01810, " Quality Assurance Audits and
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Surveillances," Revision 2.
GDP-ZZ-01830, " Quality Assurance Planning Guides (QAPGs),"
Revision 0.
(3) Quality Assurance Audit Schedule 1987, 0QM-87-005, January 14, 1987.
(4) Audit Reports.
70T03, Audit'of Training, Qualification, and Performance.
- AD5A8605A, Audit of Non-Licensed Training and Performance.
- G170.07-8609P, Audit of the I&C Department.
- 70C03, Qualifications and Training.
(CorporateOffice)
AD5A86028, Cesign Control.
- AD5A8603B, Design Change Implementation.
- AP-87-001, Design Change Development.
- AP-87-003, Corrective Action and Nonconforming Item Control.
- G170.10-8610P, Planning and Scheduling of Corrective
and Preventative Maintenance.
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A05A8607C, Maintenance.
- AD5A8512A, The I&C Department.
- ADSA8508C, Callaway Preventive Maintenance Program.
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AD5A85070, Callaway Maintenance and Instrument and Control
Programs.
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b.
Results of Inspection-
-Qualification and certification of site auditing personnel were reviewed by the inspector.
Six. lead auditors from three different onsite QA support groups were sampled.
Certification records met the requirements of ANSI N45.2.23.
Thirteen " Request for Corrective Action" items issued as a result ofauditingactivityinauditreports,werefollowedthrough to resolution and close out.
All items appeared to be adequately-handled and closed out in a timely fashion.
L The Reference Tracking System was reviewed'by the inspector to assess the system for tracking 0QAM changes to all applicable sub-tier documents and to gain assurance that all applicable seb-tier documents were also revised.
Although several instances e
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of change notifications were observed, no example was found where actual changes to sub-tier procedures had been made.
The inspector learned that the Emergency Response Program System for reference documents was complete and in place.
This computerized system was reviewed by the inspector.
In. response to questions, the inspector learnedthatasimilarreferencesystemwasplannedforthe0QAM; however, programming had not been done.
This. item remains open for review at a later date.
(483/87012-02).
Thirteen audit-reports, listed above, were reviewed by the inspector.
Attributes were assessed and found adequate as follows:
l (1) The planned schedule adequately assured timely coverage of the applicable program.
(2) Corrective action was taken for identified deficiencies in a timely fashion.
(3) Audits were distributed to management personnel.
l (4) Checklists were utilized in the performance of audits.
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(5) Basic requirements and acceptance criteria were available and l
usedinconjunctionwiththeaudit.
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l (6) Followup items were completed in a timely fashion.
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No violations or deviations were identified.
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Corrective Action (92720)
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l ThisinspectionwasperformedtoassesslicenseeQAauditingofcorrective
action, and applicable information reported to management personnel.
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' Reference Documents-a.
(1) Operations Quality Assurance Manual (0QAM), Revision 9.
Section 16, Corrective Action
Section 18, Auditing
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(2) Quality Assurance Audit Schedule, 1987, 0QM-87-005, January 14, 1987
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(3) Callaway Administrative Procedures GDP-ZZ-00100, " Quality Assurance Stop Work Actions,"
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GDP-ZZ-01810, " Quality Assurance Audits and Surveillances,"
Revision 2.
- APA-ZZ-00007, " Quality Assurance Organization,
Responsibility, and Conduct of Operations,"
Revision 0.
(4) Audit Report Number AP87-003, QA Audit of Corrective Action and Nonconforming Item Control, b.
Results The inspector reviewed the above listed audit report.for the following attributes.
(1) Utilization of checklists.
(2) Issuance of. Requests for Corrective " ^ ions (RCAs).
(3) Followup activity where applicable.
(4) Distribution to Management.
The ins! ector concluded that the corrective action program was being
adequately' audited.
The inspector also reviewed the Quality Assurance Division's, semi-annual report for the period July 1 through December 11, 1986.
Included was Trend Analysis Report ~No. 6! Potential areas of
concern were highlighted and' charted.
The report, addressed to the Vice-President Nuclear, appeared to be an effective management
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reporting tool.
No violations or deviation were identified.
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5.
Maintenance Assessment (62700 and 62702)
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This. inspection was conducted to measure the effectiveness of the licensee auditing program to measure the ability of the maintenance staff to conduct a maintenance program respcnsive to regulatory requirements, technical specifications, application commitments, and-industry ~ guides or standards.
a.
Reference Documents (1) Callaway Administrative Procedures.
APA-ZZ-00549, " Reliability Program," Revision 1.
- APA-ZZ-00340, " Surveillance Program Administration,"
Revision 8.
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APA-ZZ-00142, " Post Trip Review Program," Revision 0.
(2) Callaway Licensee Event Reports.
j 86-022-00, Feedwater Isolation Valve Card Failure.
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86-037-00, Spurious Turbine Driven - Auxiliary Feedwater-.
Actuation.
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86-038-00, Valve Leakage Results in Hi Containment RAD
Levels and ESF Actuations.
j 86-022-01, (Followup of abcve listed items).
- t (3) Callaway Audit Reports.
AD5A8507D, Callaway Maintenance and Instrument and Control
Programs.
AD5A8508C, Callaway Preventative Maintenance Program.
- AD5A8512A, I&C Department.
- AD5A8605A, Audit of Non-Licensed Training and Performance.
- A05A8607C, UEN0 Maintenance Program.
- G170.07-8609P, Audit of the I&C Department.
- f G170.10-8610P, Planning and Scheduling of CA&PA Activities.
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(4) Selected Callaway Request for Corrective Actions (RCAs).
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P8508-129, Inadequate Corrective Action.
- P8508-131, Inadequate MTT Procedures.
- P8512-205, Failure to Maintain Documents
as QA Records.
P8512-206, Inade_quate Trending Procedure.
- Results
The inspector reviewed the audit report about non-licensed training and performance.
The audit objectives were to verify the following:
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Personnel requalified as required.
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Adequate qualification documentation exits.
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Compliance with established criteria for education and experience used for qualification.
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Qualificationcardstandardsandtrainingrelatedtoappropriatejob and task analysis.
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Mechanisms exist for feedback of operating experience.
The inspector concluded that a thorough, in-depth audit was performed and the conclusion, traihing and qualification had been adequately implemented.
The inspector determined that the audits performed of the implemented program activities for both corrective and preventive maintenance programs supported the licensee's conclusion that the maintenance program was adequately implemented.
Four Requests for Corrective Action (RCA) were reviewed by the inspector.
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The identified concerns, responses to the RCAs, followup, and close out actions all appeared to be extensive, timely, and adequate.
The inspector identified no concerns.
No violations or deviations were identified.
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Design Changes (377028)
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This inspection was conducted to measure the effectiveness of the licensee s auditing program to:
measure the adequacy of program controls for design and modification ~ changes; assess the qualification and training of design personnel; and determine adherence to regulatory requirements, technical specifications, application commitments, and industry guides and standards.
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a.
Reference Documents (1) Callaway Nuclear Function Directive Number NFD-5,
" Qualification and Training," Revision 0.
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(2) Callaway FSAR Site Addenda, Section 13.1.1.3, " Qualifications
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of Technical Support Personnel".
(3) Callaway Technical Specification Interpretation Number 24, " Audits".
(4) Callaway Administrative Procedure APA-ZZ-00126, "Callaway Plant l
Training Manual," Revision 3.
(5) Callaway Audit Reports.
ADSA86028, Design Control.
- l AD5A86038, Design Change Implementation.
- AP87-001, Design Change Development.
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l 70C03, Training,. Qualification and Performance General
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l 70T03(G170.20-8609G), Training, Qualification ~and
Performance General Office.
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(6) Selected RCAs and Checklist Items.
P8603-029, Design Reviews Not Performed.
- P8603-028, NMRs Not Processed as Design Changes.
- P8604-061, Improper Deviation from CMP (Callaway
Modification Package) Design.
RP87-005, Design Change Documentation Does Not Meet
Commitments.
Checklist Item No. 23 (from Report No. AD5A8603B) Review of
Callaway Systems and_ Components Q-List (CSCQL).
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b.
Results Review by the inspector of the audit reports and the related RCAs established that:
(1) Adequate verification of design change program implementation was conducted.
(2) ' Corrective action was adequately performed.
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(3) One RCA, Number P8507-108, reviewedinconjunctionwithRCA Number P8603-028 remained unresolved for an extended period of time.
In-depth review by the inspector established that corrective action resolution evolved over a longer period of time.
Although the followup had not been completed, the inspector considered the resolution adequate.
(4) Training and qualification of the engineering staff was reviewed.
The licensee had committed to an effective training program in Nuclear Function Directive Number NFD-5, Revision 0.
Moreover, as stated in Section 13.1.1.3 of the Callaway FSAR Site Addendum, the technical staff of the Manager, Nuclear Engineering, was to include personnel trained and experienced as set forth on Page 13, 1-13 of the FSAR.
The inspector reviewed the licensee's audits of these commitments with the following results:
Corporate Audit Number 70C03, September 11, 1985, indicated
no discernable information.
Audit Report Number AD5A8602B, March 27, 1986, indicated
no auditable information.
Corporate Audit Number 70T03, October 17, 1986, provided
to the inspector just prior to the exit meeting established that seven nuclear function personnel located at the corporate office had the necessary training degree to comply with FSAR-SA, Section 13.1.1.2.1.
The inspector was unable to determine if training or qualifications had been adequately verified by the licensee.
This matter is unresolved and will be reviewed further during a future inspection.
M3/87012-03).
No violations or deviations were identified; however, there was one unresolved item.
7.
Open Items Open items are matters that have been discussed with the licensee, which will be reviewed further by the inspector, and involve some action on the part of the NRC or licensee or both.
Open items disclosed during this inspection are discussed in Paragraphs 2 and 3b.
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Unresolved Items An unresolved item is a matter about which more information is required in order to ascertain whether it is an acceptable item, and open item, a deviation, or a violation.
An unresolved item disclosed during this inspection is discussed in Paragraph 6b(4).
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9.
Exit Interview-The Region III inspector met with the licensee representatives (denoted in Paragraph 1) at the conclusion of the inspection on April 16, 1987.
The inspector summarized the purpose-and findings of the inspection. The inspector also discussed the likely informational content of the inspection report with regard to documents or processes reviewed during the inspection.
The-licensee representatives did not identify _any such documents / processes as proprietary.
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