ML20132G902

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QA Program Insp Rept 99900511/85-01 on 850506-10. Noncompliance Noted:No Documented Procedure Existed for Control of Mixing Chemical Spray Solution Used During Design Basis Event Testing & Monitoring Solutions Ph
ML20132G902
Person / Time
Issue date: 06/13/1985
From: Moist R, Potapovs U
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:
Shared Package
ML20132G819 List:
References
REF-QA-99900511 NUDOCS 8507190486
Download: ML20132G902 (13)
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{{#Wiki_filter:* ORGANIZATION: CORPORATE CONSULTING & DEVELOPMENT COMPANY, LTD RESEARCH TRIANGLE PARK, NORTH CAROLINA REPORT INSPECTION INSPECTION NO.: 99900511/85-01 DATE(S): 5/6-10/85 ON-SITE HOURS: 67 CORRESPONDENCE ADDRESS: Corporate Consulting & Development Company, Ltd. ATTN: Dr. J. R. Yow President P.O. Box 12728 Research Triangle Park, N.C. 27709 ORGANIZATIONAL CONTACT: Mr. Carson Blanton, Jr., QA Manager TELEPHONE NUMBER: (919) 362-8800 PRINCIPAL PRODUCT: Engineering, consulting, and testing services. NUCLEAR INDUSTRY ACTIVITY: Corporate Consulting and Development Company, Ltd. (CCL) provides engineering consulting and testing services to the nuclear industry for seismic analysis, testing, and nuclear environmental qualifications of equipment. e I. ASSIGNED INSPECTOR: G M 8 J7fu M YJM4/ff5 Rf N. Moi'st, Equipdent Qualification Inspection Date Section (EQIS) OTHER INSPECTOR (S): G. T. Hubbard, EQIS f APPROVED BY: b@? 6 -l 3 -{I U. Potapovs, Chief, EQIS', VP8 Date INSPECTION BASES AND SCOPE: A. BASES: Appendix B to 10 CFR Part 50 and 10 CFR Part 21. 8. SCOPE: This inspection consisted of : (1) a technical evaluation of equipment qualification (EQ) test activities for safety-related equip-ment, (2) witnessing of inprocess EQ testing; and (3) verification of implementation of the quality assurance (QA) program. PLANT SITE APPLICABILITY: Brunswick 1 & 2 (50-324 and 50-325) \\ 8507190486 850710 PDR GA999 EECCCDC i 99900511 PDR

3 ORGANIZATION: CORPORATE CONSULTING & DEVELOPMENT COMPANY, LTD RESEARCH TRIANGLE PARK, NORTH CAROLINA REPORT } INSPECTION NO_- 99000511/95-01 1 SESULTS: 3 AGE 2 of 5 A. VIOLATIONS: None N s B. NONCONF0PNANCE: 1. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and section 5 of the Quality Assurance Manual (QAM), no documented procedure existed for the control of mixing the chemical spray solution used during design basis event testing and monitoring the solution's PH. C. UNRESOLVED ITEMS: None D. OTHER FINDINGS OR COMMENTS:

===1. Background=== Carolina Power ar.d Light Company (CP&L) contracted with CCL to conduct EQ test (vibration aging, thermal aging, radiation, seismic and High Energy Line Break (HELB)) of limit, control and pushbutton switches, terminal blocks, and solenoid valves. Test requirements were defined in three Patel Engineers Qualification Test Plans (QTPs), (PEl-TR-83-4-25 REVC-QTP for switches, PEl-TR-83-4-26 REV C-QTP for terminal blocks, PEl-TR-83-4-27 REV E - QTP for solenoid valves as required by CP&L purchase order (P0) to CCL. CCL wrote detailed test proce-dures for Qualification Testing based on the three Patel Engineers QTPs. These Qualification Tests were performed under CCL Job Number (JN) 1857. 2. Post HELB Inspection and Functional Tests for JN 1857: The NRC inspectors observed and visually inspected switches and terminal blocks after the test chamber cover was removed and again after the removal of the specimens from the chamber. Visual inspection of a DC terminal block GE CR151D showed a build-up of foreign material between two terminal lugs. Following functional testing (FT) the CP&L representative sent the terminal block to a lab for analysis of the foreign material. CCL personnel took photos of the terminal blocks to document their conditions. The inspectors witnessed post HELB FT (insulation resistance and continuity measure-ments) for the switches and terminal blocks. The NRC inspectors reviewed detailed Test Procedure (TP) 1857-1-1/REV 1/FT for switches, TP 1857-1-2/REV 1/FT knob and key switches, TP 1857-1-3/REV 1/FT pushbutton switches, TP 1857-1-4/Rev 1 FT indicating lights and l

ORGAhiZATION: CORPORATE CONSULTING & DEVELOPMENT COMPANY, LTD RESEARCH TRIANGLE PARK, NORTH CAROLINA REPORT INSPECTION wn - ooonn;t1/RR_n1 QF9m TS-PAGE 3 of 5 TP 1857-1-7/REV 3/FT terminal blocks. It was determined that the tests and inspection activities were being performed in accordance with the detailed test procedures and CCLs QAM Revision 1 dated 12-10-84. The NRC inspectors also evaluated the calibration status and accuracy of the instrumentation used to perform the Post HELB FT by review of instrumentation calibration records. 3. Test Results of Post HELB FT for JN 1857 FT was started May 7, 1985, and was completed on May 9, 1985. During the testing, four test anomalies were identified and were documented by Record of Anomaly (ROA) per CCL's QAM. The four ROAs are sumarized as follows: (1) The knob on a Honeywell oil tight manual control switch would not turn clockwise or counterclockwise. (2) The pushbutton on a GE oil tight pushbutton switch could not be depressed. (3) A Honeywell limit position switch OP-AR did not meet the accep-tance criteria of the QTP for IR measurements. f (4) A Honeywell limit position switch OPD-AR did not meet the accep-tance criteria of the QTP for continuity measurement. CCL and CP&L are currently reviewing and evaluating the four ROAs. The results of the evaluation will be reviewed in a future inspection. 4. Technical Evaluation The NRC inspectors performed an in-depth technical evaluation and review of previous testing conducted on three test programs for qualification of safety-related electrical equipment. The following 'qable sumarizes the test programs examined including equipment type an6 types of documents examined. Test Program Equipment Type Documents Examined 1857 Solenoid valves; terminal QTP,TPs,P0's, blocks; switches; and receiving slips, indicating lights. test data, test monitor log sheets. N

ORGANIZATION: CORPORATE CONSULTING & DEVELOPMENT CGMPANY, LTD RESEARCH TRIANGLE PARK, NORTH CAROLINA REPORT INSPECTION NO.- 99900511/85-01 RESULTS: PAGE 4 of 5 Test Program Equipment Type DocumeMs_ Examined 1859 Electro switches, indi-TR, calculation cating lights, fuseblock, file for ther:x ! fuse, terminal block & aging, P0s, spect-enclosure, fication test plan. 1914 Electro switches, indi-TR cating lights The NRC inspectors reviewed the EQ process prescribed in each test plan and reviewed test results, including the bases for accelerated thermal aging and radiation, and verified calculations. Each of the three EQ test plans and related engineering documents were examined for the following: a. Adequate test instrumentation and their accuracies were described and used to meet the requirements of NUREG-0588/IEEE-STD-323/1974. b. Equipment interfaces were addressed. c. Test acceptance criteria were established as described in the test specification or in the design engineering documents, such as calculations and engineering letters to meet the requirements of NUREG-0588/IEEE-STD-323/1974. d. Same equipment was used for all phases of testing and represented a standard production item. e. Environmental conditions were established and described (e.g., pressure and temperature profiles, and thermal aging factors were consistent with those outlined in the test specification or test plan). f. Test results were adequately reduced and evaluated against established acceptance criteria described in customer test specifications or purchase orders and these requirements had been met. g. All prerequisites for the given tests as outlined in the test specification had been met. ~-t

d ORGANIZAT10N: CORPORATE CONSULTING & DEVELOPMENT COMPANY, LTD RESEARCH TRIANGLE PARK, NORTH CAROLINA REPORT INSPECTION NO - 94400511/85-01 PESULTS-PAGE 5 of 5 h. Test equipment included a description of all material, parts, and subcomponents. i. ROAs were properly documented. No nonconformances were noted during this review. 5. Other Testing The NRC inspectors observed a test set up for loss of Coolant Accident (LOCA) testing of conduit seals and anti-wicking splices for cables. During the observance of the test setup the NRC inspector determined, after interviews with CCL personnel, that CCL did not have a documented procedure for the control of mixing the chemical spray solution and monitoring the solution's PH. (see nonconformance B.1) The QA Manager provided the NRC inspectors prior to leaving CCL a copy of a new data sheet called " Chemical Spray Data Sheet Form TF-114" which showed calculations of the mixing ratios, initial PH and Daily PH readings, a revised test monitor log which now verifies that Form TF-114 has been prepared, and a revised Accident Simulation testing checklist which now contains a check for preparing Form TF-114 I r - - - ~ -.,.

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