ML20216C252

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Insp Repts 50-445/87-02 & 50-446/87-02 on 870101-0228.No Violations Noted.Deviations Noted:Several Concrete Pours Not Included in Population Items List & Documents Missing from Issue Specific Action Plan Vii.C Projects File
ML20216C252
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 06/22/1987
From: Barnes I, Ellershaw L, Hale C, Spessard R, Wagner P
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20216C144 List:
References
50-445-87-02, 50-445-87-2, 50-446-87-02, 50-446-87-2, NUDOCS 8706300248
Download: ML20216C252 (34)


See also: IR 05000445/1987002

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. APPENDIX'B'

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'NRC COMANC 5 PEAK RESPONSE TEAM-ACTIVITIESLINSPECTION REPORT

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', e ..U. S. NUCLEAR REGULATORY COMMISSION-

4 REGION.1V,

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r NRC Inspection Report: '

50.445/87-02 Permits: . CPPR-126

< J' '50-446/87-02~ CPPR-127'

ct  ; Dockets: 50-4451 Category: $2E

50-446--

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, Construction' Permit-

Expiration Dates: ..

..' . Unit 1: August.1, 1988..

1 ' Unit 2: August'1, 1987-

Applicant: TV Electric.

tSkyway Tower

400 North Olive Street

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Lock. Box 81 <

Dallas,: Texas .

75201

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Facility Name': Comanche Psak Steam Elect'ric Station-(CPSES),:

Units'l'& 2

Inspection At: . Glen Rose,-Texas

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Inspection Conduct d:2 January 1 through. February 28, 1987-

Inspectors:- n ~

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- - L' E. Ellershaw, Reactor. Inspector, Region IV Dath /

CPSES Group _ . .

E (paragraphs 2.a-f, 2.h-1, 2;n, 2.s, 3.c,

4.a,'and 4.b)

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C. J. %Te, Reactor Inspector, Region IV Date / i

CPSES Group

(paragraphs 2.g, 2.m, 2.q-r, 3.b, 3.d, and 5)  ;

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0. [U64 &

P..C. Wagner, React 6r Inspector, Region IV

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Date

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CPSES Group i

(paragraphs 2.0 p, 3.a, and 4.a)

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8706300248 870622 o

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, PDR ADOCK 05000445 .

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Consultants: EG&G J. Dale (paragraphs 2.a-f, 2.h, 2.j-1, and 4.b)  !

A. Maughan paragraphs 2.0-p and 4.a)

W. Richins paragraphs 2.n and 4.a)

V. Wenczel paragraph 5)

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Parameter -K.J.Graham

Birmingham (paragraphs

(paragraphs 2.1, 2.s,2.g,

and2.m.

3.c 2.q-)r, 3.b, and 3.d)

D. Jew (paragraph 4.a)

Reviewed By: G /15 /97  :

R. L. Spessard, Deputy Director, Divisi @ of Date l

Inspection Programs, Office of Inspect 1on i

and Enforcement

Approved: " $ 7

I. Barnes, Chief, Region IV CPSES Group Date

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Inspection Summary i

Inspection Conducted: January 1 through February 28, 1987 (Report 50-445/87-02;

50-446/87-02)

Areas Inspected: Nonroutine, unannounced inspection of applicant actions on

previous inspection findings, Comanche Peak Response Team (CPRT) Issue-Specific

Action Plans (ISAPs), assessment of VII.c populations, and the ISAP sample

selection process. l

Results: Within the four areas inspected, two deviations (several concrete

pours were not included on the Population Items List, paragraph 4.a.[3]; and

documents missing from the ISAP VII.c project files, paragraph 4.a.[4]) were

identified.

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DETAILS i

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'1. Persons Contacted

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    • J. M. Ayres, Quality Engineering (QE) Supervisor, TV Electric
      • R. P. Baker, Regulatory Compliance Manager, .TV Electric
      • J. L. Barker, Engineering Assurance Manager, TV Electric -
    • J. W. Beck, Vice President, TU Electric j
    • G. L. Bell, Nuclear Licensing, TV Electric 1

P. Boortz, Engineering Assurance Supervisor, Evaluation Research I

Corporation (ERC) 1

D. Boultan, Population Engineer, ERC -j

D. Boydston, Issue Coordinator, ERC

    • E. J. Brabazon, Deputy Program Manager, CPRT

T. Braudt, CPRT, TV Electric

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J. A. Buck, Senior Review Team (SRT), CPRT l

    • F. G. Burgess, CPRT Project Manager, TU Electric

R. E. Camp, Unit 1 Project Manager, TU Electric

      • W. G. Counsil,. Executive Vice President, TV Electric
      • R. D. Delano, Nuclear Licensing Engineer, TU Electric

D. Ferguson, Results Report Review Committee Chairman, CPRT t

    • J. R. Gelzer, Issue Coordinator, ERC l
    • M. R. Gross, Jr., Staff Member, CPRT  !
    • J. Guibert, SRT, CPRT  !
      • P. E.'Halstead, Site Quality Control-(QC) Manager, TV Electric j
    • J. Hansel, Review Team Leader (RTL), ERC q
      • T. ' L. Heatherly, Regulatory Compliance Engineer, TU Electric j
    • G. S. Keeley, Nuclear Licensing Manager, TU Electric ,

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      • J. E. Krechting, Director of Engineering, TV Electric  ;

D. McAfee, Quality Assurance (QA) Manager, TV Electric

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J. McNally, Population Engineer, ERC

J. W. Muffett, Executive Assistant, Engineering & Construction, .j

TU Electric i

      • L. D. Nace, Vice President, TV Electric i
    • W. Nyer, SRT, CPRT

A. Patterson, Issue Coordinator, ERC )

      • D. M. Reynerson, Unit 2 Project Manager, TV Electric

G. W. Ross, Issue Coordinator, ERC ,

R. K. Sanan, Issue Coordinator, TERA i

J. Schauf, Construction Evaluation Engineering Group Supervisor, ERC  !

      • C. E. Scott, Startup Manager, TU Electric
    • J. Smith, Operations Staff, TV' Electric
      • M. R. Steelman, CPRT Support, TU Electric
    • J. F. Streeter, QA Director, TV Electric 3

J. Tableriou, Population Engineer, ERC  !

T. G. Tyler, CPRT Program Director, TV Electric

C. Vincent, Issue Coordinator, ERC

F. Webster, Engineering Statistics Advisor, CPRT ]

D. R. Woodlan, Licensing Supervisor, TU Electric j

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      • J. E. Wren, QC Services Supervisor, TV Electric

J. E. Young, Issue Coordinator, ERC

R. Zill, QA & Personnel Supervisor, ERC

The NRC inspectors also interviewed other applicant employees during this i

inspection period. l

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  • Denotes personnel present at the February 10, 1987, exit interview. l
    • Denotes personnel present at the March 3, 1987, exit interview.  !
      • Denotes personnel present at both of the above exit interviews.

2. Applicant Actions on Previous Inspection Findings

(0 pen) Open. Item (446/8513-0-09): Potential deviations were

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identified by ERC concerning:~ (1) weld location,.(2) undersize welds,. 'j

(3) welding not per weld symbol, and (4) violation of minimum thread i

engagement. These conditions were documented on Deviation Reports  !

(DRs) I-S-HVDS-109-DR-1, DR-2, DR-3,'and DR-4 and incorporated into  !

Nonconformance Report (NCR) M86-250134X. This item will remain open

pending disposition of the NCR. i

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Since these conditions were determined.to be not nonconforming, this  !

item is closed.

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b. (0 pen) Open Item (445/8514-0-15): Potential deviations were j

identified by the ERC inspector concerning a missing color code and 1

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the allowable distance between color code marks was exceeded. These

were identified on DRs I-E-ININ-066 DR 1 and DR 2 and subsequently on

NCR I-85-102025SX. This population was reinspected at a later date

for additional attributes and the package designation changed from

I-E-ININ-066 to I-E-ININ-066R. The reinspection generated one

additional DR, DR I-E-ININ-066R-DR-3, which resulted in the issuance

of NCR I-86-101916X. This NCR also incorporated the previously

identified NCR. This item will remain open pending disposition of  ;

the NCR. I

c. (0 pen) Open Item (445/8514-0-16): A potential deviation was I

identified by the ERC inspector concerning location of sending

Units 1-LS-6712 and 1-LS-6717 being reversed on the tank for

package I-E-ININ-069. This was subsequently identified on-

DR I-E-ININ-069-DR-1, and NCR I-85-101890SX. Because of added

attributes, this population was reinspected and the NCR superseded by

NCR I-86-101915X. This item will remain open pending disposition of

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the NCR.

d. (Closed) Open Item (445/8514-0-24): A potential deviation was

identified by the ERC inspector concerning a missing nameplate and an

actuator spring that could not be located on the damper associated

with reinspection package I-M-HVIN-043. A subsequent inspection by

another ERC inspector revealed the existence of the required

nameplate and also identified from review of vendor I

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Drawing 5800-M-027, Revision CP-1, that the damper was a motor

actuated fail-safe damper, Model No. SL-100-ML-N, which does not

utilize a spring for activation._ The NRC inspector confirmed by

examination of the damper and review of the vendor drawing that the

results of'the subsequent ERC inspection were correct. This item is ,

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closed. '

e. (0 pen) Open Item (445/8514-0-28): A potential deviation was

identified by ERC concerning an undersize horizontal brace. This-

condition was identified in DR.I-S-HVDS-023-DR-4 and incorporated

into NCR M-86-100321SXR1. This item will remain open pending

disposition of the NCR.

f. (0 pen) Open Item (445/8514-0-29): A potential deviation was

identified by ERC concerning undersize fillet welds. This condition

was identified in DR I-S-HVDS-041-DR-4 and incorporated into

NCR M-85-101991XR2. This item will remain open pending disposition

of the NCR.

g. (Closed) Open Item (445/8516-0-12; 446/8513-0-08): The ERC

nonconformance evaluation checklists did not provide for the

evaluation of the technical adequacy of NCR dis'ositions.

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This ERC QA/QC RTL'and the VII.a.2 issue coordinator has stated that

evaluation of the technical adequacy of NCR dispositions is outside l

the scope of ISAP VII.a.2. The applicant has, however, initiated a

program (performed by Stone & Webster Engineering Corporation) to )

evaluate the disposition of 300 NCRs with use-as-is or repair  !

dispositions for technical adequacy. The evaluations assessed the

NCR dispositions to determine: (1) if the disposition fully addressed .

the nonconformance; (2) if an adequate technical justification was I

provided; and (3) whether the disposition block was correctly

identified. To provide further assurance, the applicant has decided i

to expand its program to assess the technical adequacy of the

remaining NCRs with these disposition categories. This activity will

be overviewed by TERA as an independent third party. NRC inspection

of this' process will be reported in a subsequent inspection period.

h. (0 pen) Open Item (445/8516-0-15): Potential deviations were

identified by the ERC inspector concerning locknuts missing from

clamp bolts and a bolt hole was incorrectly located. This condition

was subsequently identified in DRs I-S-0S42-25-DR-1 and DR-2 and

incorporated into NCRs M-23216NR1 and M-25338N, respectively. This

item will remain open pending disposition of the NCRs.

i. .(Closed) Deviation (445/8516-D-35): The ERC inspector failed to

record the presence of existing additional field welds to those

specified on the drawing for Verification Package I-S-LBSR-041 and

did not provide objective evidence of reinspection. The deviation

resulted from inspection personnel not being able to distinguish

vendor welds from field welds on vendor supplied components. ERC

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Quality Instructions (QIs) QI'019, QI-027, and QI-029 were ' revised to

incorporate inspection requirements for these welds. Weld

inspections performed prior to the procedure change were reviewed and

supplemental inspection. instructions were. issued on a case-by-case

basis to assure compliance with revised procedural requirements. The

NRC inspector reviewed the corrective action taken and concluded that

the revised instructions should prevent recurrence.

j. (0 pen) Open Item (445/8516-0-38): Potential deviations were

identified by ERC concerning: (1) weld symbols and locations,

(2) undersize welds, and (3) a Hilti Kwik Bolt embed violation.

These conditio'sn were documented in DR I-S-HVDS-029-DR-1 and DR-2,

and incorporated into NCR M-85-102014X. This item will remain open

pending disposition of the NCR.  !

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k. (0 pen) Open Item (445/8516-0-39): Potential deviations were

identified by ERC concerning: (1) incorrect member dimensions,

(2) incorrect weld configuration, (3) incorrect weld size,

(4) incomplete fusion in welds, and (5) violation of weld undercut

criteria. These conditions were documented in DRs I-S-HVDS-089-DR-1,

DR-2, DR-3, DR-4, DR-5, and DR-6. These DRs were then. incorporated

into NCR M85-102027X for DR-1 through DR-5 and NCR M86-103774X for

DR-6. This item will remain open pending disposition of the NCRs.  !

1. (0 pen) Open Item (445/8516-0-40): Potential deviations were

identified by ERC concerning: (1) dimension violations, (2) incorrect

duct dimension, (3) incorrect orientation, (4) welds were undersize, )

and (5) incorrect weld profile. These conditions were documented in

DRs I-S-HVDS-103-DR-1, DR-2, DR-3, DR-4 AND DR-5. These DRs were

then incorporated.into NCR M85-101991X. This item will remain open

pending disposition of the NCR.

m. (Closed) Violation (445/8518-V-03; 446/8515-V-02): Item A.1, failure

to certify an inspector in accordance with procedural requirements.

As corrective action for this violation, the applicant committed to  ;

revise Procedure CP-QP-2.1, " Training of Inspection Personnel," with  !

date of full compliance by May 21, 1986. The procedural revision was

to provide for identification of qualification responsibility and u

authority of Level III personnel involved in training and s

certification activities including those areas where a cross-over of  !

. qualification authority existed. The violation was issued due to the l

failure to identify this cross-over authority. The NRC inspector i

verified that CP-QP-2.1, Revision 21, dated May 8, 1986, and

associated memorandum TUQ 3748 dated May 12, 1986, provide for this

identification of cross-over authority. This item is closed.

Item A.2, failure to follow procedures when justifying waivers of

on-job training (0JT) in the certification of four QC inspectors.

The NRC inspector has reviewed the information provided in the

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, supplementa1 re'sponse-to this violation. This review and ,

. . reinspection of the files for the four QC. inspectors: verified that-

. justification other.than ". .-2 hours OJT and previous related

inspection activity.. . ." was. included.' The justification on the

waivers included.".:. . demon'stration of practicalJfield ability to

, the satisfaction of a certified Level II." This. demonstration

. provided ". . ." assurance'that the individual does have ' comparable'

or ' equivalent'. competence to that which would have been

. gained . . ..." Therefore, specification.on the waiver of the

previous related inspection activity was'not required in these cases.

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Since'the required information was included elsewhere in' the q

certification files, a violation did not occur in this example'and q

this item.is closed.' U

n. ;(Closed) Open Item (445/8603-0-15): This open item: addressed.

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i  : inspector certification documentation for fill and backfill

placements. ERC . issued DR R-S-FILL-GEN-DR-1 regarding inspector

certification-for the safe' shutdown impoundment dam construction for

the period April 24, 1976, through April'19, 1977. Inspector

certification documentation for Freese & Nichols Consulting; j

Engineers (F&N)'a'nd Mason & Johnson Associates, Inc. (M-JA) could not 1

be located during the initial ERC documentation reviews.

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TU Electric subsequently requested copies of. certification records 'l

from F&N and M-JA. These documents were obtained and are being

transmitted to the Permanent Plant Records Vault (PPRV). The NRC j

inspector reviewed these inspector certification documents and found' 1

.that the inspection personnel were qualified to perform the  :

inspections and/or. laboratory tests. This item is closed. 1

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o. (Closed) Unresolved Item (445/8607-U-17): Incomplete craft

installation procedure instruction. NRC ins ector review of- ^

Revision 5 of Construction Procedure EEI-8, p' Class 1E-and non-Class

Cable Terminations," had identified the omission of installation i

requirements for uninsulated cable splices. This omission ~was noted

in NRC Inspection Report.50-445/86-07; 50-446/86-05 during the

evaluation of.CPRT commitments related to preinsulated environmental {

sealed (PIES) splices. During-this report period, the NRC" inspector

reviewed Revision 6 of EEI-8 dated September 23, 1986, and determined

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that adequate provisions for all types of splices had been

incorporated therein. It should be noted that the adequacy of the ,

splices installed under the old procedure revisions is being

addressed in ISAPs I.a.2, " Inspection Reports on Butt Splices;"

I.a.3, " Butt Splice Qualification," for PIES splices; and I.a.1, ,

" Heat Shrinkable Insulation," for uninsulated splices.

p. (Closed) Unresolved Item (445/8607-U-18): Incomplete inspection '

procedure instructions. In addition to revising EEI-8, the CPRT also

committed to having certain inspection requirements for PIES splices

installed in control boards incorporated in the QC inspection  !

procedure, QI-QP-11.3-28, " Class 1E Cable Terminations." The NRC

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inspector review of Revision 28 of this procedure had indicated that

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other. types of splices and PIES splices installed in locations other I

than control panels were not subjected to the same requirements as

the PIES splices in control panels. Further NRC inspector review of j

the applicable facility commitments and of Revision 31 to  !

QI-QP-11.3-28 found that all of the applicable provisions not J

previously included had been incorporated into the' procedure. It

should be'noted that the adequacy of the splices instal. led under the { ;

old procedure revisions is being' addressed in ISAPs I.a.2, i

" Inspection Reports on Butt Splices;" I.a.3, " Butt Splice

Qualification," for PIES splices; and I.a.1, " Heat Shrinkable

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Insulation," for uninsulated splices. j

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q. (Closed) Violation (445/8615-V-06): Failure of the Unit 1 PFG to f

provide specific instructions for the control of design documents

issued for extended time periods.

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The NRC inspector verified tha!. Procedures CP-CPM-7.4 and CP-CPM-7.4A i

were revised July 25, 1986, to provide instructions for the control

of design documents issued for extended time periods. As stated in

the response, these two procedures were superseded by issuance'of

Procedures CP-CPM-7.1 and CP-CPM-7.1A on December 15, 1986, when the

Unit.1 and 2 PFGs were combined. The NRC inspector verified that a

daily review of the Package Inventory Card for document packages

issued for extended time periods was required in these procedures and

that the requirement applied to both Units 1 and 2. These procedural i

revisions provide the required controls. This item is closed.

r. (Closed) Violation (445/8615-V-07; 446/8612-V-07): Failure to I

control the activity by which the onsite fabrication shop provides

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inspection traceability of identical shop fabricated items. j

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NRC review of Procedures CP-CPM-7.3A, " Material

Storage / Identification for Structural Steel Fabrication,"' Revision 0,

DCN #2, dated August 12, 1986, and QI-QP-11.14-1, Revision 24, dated

July 28, 1986, verified that these procedures were revised to

incorporate methods to control inspection traceability of identical

shop fabricated items. Since the violation was issued for failure to

procedurally control the activity and no hardware deviations were

noted during the previous inspection, the above revisions to the )

applicable procedures close this item. '

s. (0 pen) Open Item (445/8615-0-11): During inspection of Verification

Package I-M-MEIN-035, the NRC inspector identified that an equipment ,

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foundation anchor bolt nut was not bearing load and that a 1/4" gap

existed between the anchor nut and the load bearing mating surface.

Subsequent NRC review of ERC overview inspection documentation

revealed that an ERC overview inspector had already identified the

deviating condition and that DR I-M-MEIN-035-DR2 had been issued and I

validated, resulting in the issuance of NCR M-23094 NR-2. This item

remains open pending disposition of the NCR.

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3.' :CPRT-ISAPs (excluding'ISAP VII.c)

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a. Heat-Shrinkabl~e Cable Insulation Sleeves (ISAP I.a.1)

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During this: inspection _ period,.the activity. identified by NRC

Reference.01.a.01.07 was. inspected as-follows:

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!: Establish' Sampling Plan / Select Sample (NRC Reference'01.a.01.07)-

.The NRC inspector reviewed the CPRT: files and determined that a

sample of 128. heat'shrinkab'le. insulation. sleeves was. selected by the

CPRT for inspection from 'a total of 1359 locations listed in the

action plan. A detailed dis'cussion;of the sample selection process

for this ~ISAP .is contained in paragraph 5.b(1) below. ,

Since the:. sample selection process was determined to adequately

fulfill the CPRT commitments, this activity and NRC inspection is

complete. '

No violations'or deviations were identified.

b. QC Inspector Qualifications (ISAP I.d.1)

.During ~ this inspection period, the NRC inspector inspected the

processing of DRs and the. verification of inspector qualifications

performed during ISAP I.d.1 by ERC personnel for inspectors whose '

. certifications were not found acceptable during ISAP VII.c review.

This inspection was accomplished by first reviewing.the controlling

Procedures.CPP-025, '.'QC Inspector Qualification Evaluation," and

CPP-010, " Preparation of Deviation Reports," and then performing a

detailed review of DRs related to inspector certification that were

generated during'the VII.c review process. The DR processing was

reviewed.by.the NRC inspector for'the following attributes:

-(1) Inspector certification related DRs were forwarded to the

ISAP I.d.1 issue coordinator in accordance with CPP-10.

(2) The validity of DRs was properly evaluated by the ISAP I~.d.1

issue coordinator.

(3) The transmittal of DRs was in accordance with CPP-10.

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(4) The determinations of inspector qualification for the

uncertified QC inspectors was proper and the determinations were

documented on the Inspector Certification Evaluation Summary

(ICES) form.

(5) The determinations to reinspect any previous work of unqualified

inspectors were proper and documented on a memorandum addressed

to the ISAP VII.c file as required by procedure.

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(6) Reinspections of any previous work performed by the unqualified  !

QC inspectors were accomplished in accordance with QI-005,

" Evaluation of Inspector Performance."

(7) ~ Validated DRs were transmitted to TU Electric for documentation

on an NCR/DR.

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The above procedures were determined by the NRC' inspector to provide

the necessary controls for evaluation and processing of the DRs. The

procedures specified the personnel responsible for performing the

DR evaluations and the actions required for documenting the

evaluations. The procedures also provided guidance for the

DR evaluations by reference.to ISAP I.d.1, "QC Inspector

Qualifications," and QI-005, " Evaluation of Inspector Performance,"

which detail the methods to conduct evaluation of QC inspector

certification and qualification.

The process by which ERC performs an analysis of file documentation ,

to evaluate the qualifications of QC inspectors is being inspected by  !

the'NRC under its review of ISAP I.d.1. That process is identical to

the process utilized for evaluation of inspectors identified by

ISAP VII.c, with the exception that proper QC inspector certification i

is determined by the ERC VII.c inspectors in accordance with VII.c  !

inspection / documentation review required in 28 of the 75 QIs used for

reinspections.

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During sample inspection of the document review packages, the NRC has l

been verifying whether a certification exists for the inspector of i

record, where required. l

To evaluate the system by which inspector certification / qualification l

is evaluated, the NRC selected a sample of 32 DRs concerning-

inspector certifications that were identified during the VII.c

document reviews. All 32 DRs were found to have been transmitted,

processed for validation, and maintained as specified by CPP-10 and l

CPP-025. The NRC inspector verified that the results of the I.d.1  !

issue coordinator's review of the certifications in question were J

documented on inspector certification summary forms and that  !

justification for the results was provided. l

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The NRC inspector found that of the 32 DRs selected, 28 were I

determined by the issue coordinator to be valid and 4 were determined )

to be invalid. NRC review of the packages for the four invalid DRs j

found that the certifications had existed for the certifications  !

questioned by the VII.c DRs and that documentation existed to support

the certifications.

NRC review of the packages for the 28 valid DRs found that

2 inspectors were determined by the I.d.1 issue coordinator to be

unqualified for the inspections performed. Therefore, a I.d.1 q

Phase III reinspection was specified as corrective action. The  !

26 remaining inspectors were determined by the I.d.1 1ssue

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coordinator to have been qualified for the inspections performed.  ;

The basis for the disposition of the 28 valid DRs is shown in the i

following' table:  ;

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Inspector qualified under equivalent Brown & Root (B&R) 1

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certification. 9 H

Inspector qualified under Level II and all daughter

certifications. 1 3

Inspector qualified under contractor certification other {

than B&R (e.g., R. W. Hunt). 4 1

Inspector qualified as determined by Special Evaluation i

Team /RTL review. 2

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Inspector qualified but administrative / clerical errors i

require DR. 5

Inspector qualified under previous similar certification. 5

Total determined qualified. 26 .!

Total determined not qualified and sent to Phase III

for Reinspection. 2

The NRC inspector verified during review of the validated VII.c DRs

that the I.d.1 determinations of qualifications were supported by

documented evidence of comparable prior certification, sufficient

training and examination for the inspection activity, or in the case

of the two inspectors determined by the issue coordinator's review to i

be qualified, that previous training and inspection activity was

sufficient and applicable for the certification in question.

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The NRC inspector verified that the 28 valid DRs were transmitte'd to l

TU Electric and NCRs were prepared.

As reported in NRC Inspection Report 50-445/86-22; 50-446/86-20, the

NRC inspector reviewed four reinspection matrices utilized for the

ISAP I.d.'1 Phase III reinspection of construction inspectors whose l

qualifications were determined to be unsupported by file

documentation. The four matrices were found to be in compliance with

QI-005, " Evaluation of Inspector Performance." Additionally, the NRC

inspector witnessed two field reinspections which were satisfactorily

performed by ERC inspectors in accordance with these matrices.

No violations or deviations were identified. The evaluation of DRs

pertaining to inspector qualifications generated by ISAP VII.c or

other.ISAPs will continue to be inspected by the NRC.

c. Inspection for Certain Types of Skewed Welds in NF Supports I

(ISAP V.a)

Status of NRC Inspection Activity

The NRC inspector verified compliance with the following ISAP V.a

activity commitments:

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Chronology of Inspection Methods (NRC Reference 05.a.01.00) i

The methods for QC inspection of type-2 skewed welds and the written

procedures describing the methods and means of documenting the l

inspections have changed during the construction of the CPSES

project. The technical focus of ISAP V.a is the inspection of the

geometric and dimensional characteristics of skewed welds at

' locations where simple fillet gauge measurement was not possible.

In order to determine what inspection instructions were applicable

for specific time frames, a chronology of inspection methods i

documented in QC procedures was developed by the third party to .

correlate the period of time and specific procedure revisions for  !

inspection of type-2 skewed welds.

The inspection techniques used and the methods of documenting the .

inspections of type-2 skewed welds involved the following procedures: l

QI-QAP-11.1-26: which addressed the fabrication, installation and

inspection of ASME pipe and attachments welded to the pipe.

-QI-QAP-11.1-28: which addressed the fabrication, installation and

inspection of ASME pipe supports except for attachments welded to the

pipe.

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CP-QAP-12.1: which addressed the final verification of ASME pipe

supports prior to certification (preparation of the ASME N-5 form).

Relevant historical changes affecting these quality procedures are as

follows:

QI-QAP-11.1-28: Revision 12 dated September 3, 1982, and Revision 13,

dated September 21, 1982 - Specific criteria for the measurement of

type-2 skewed welds using the scribe line technique was incorporated

into the procedure at that time. ,

QI-QAP-11.1-28: Revision 16 dated December 15, 1982 - The type-2

skewed weld inspection methodology was deleted from the pipe support

procedure,

CP-QAP-11.1-26: Revision 9 dated December 16, 1982 - The type-2

skewed weld inspection methodology was incorporated into the piping

procedure.

QCWI-1:' Dated February 21, 1983 - This B&R instruction was issued to

inform inspectors to use inspection methodology and acceptance

criteria in piping Procedure QI-QAP-11.1-26 when measuring type-2

skewed welds on pipe supports.

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CP-QAP-12.li Revision' 4 dated February 2.c1983,- and Revision' 5 dated

March 18,-1983.- These'. revisions'were issued to. initiate reinspection

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g ~o fLall' accessible structural' welds on ASME. pipe supports.

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. QI-QAP-11.'l-26: Rev'idion13datedAugust4,1983-!Theprofile

. technique for measuring' size of type-2' skewed welds was added to the-. 1

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piping. procedure.' ',

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' QI-QAP-11.1-28:' Revision;29 dated January 25, 1985.- The scribe line"

L technique for measurement of type-2 skewed fillet welds was

reincorporated into the support procedure.

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QI-QAP-11.'l-28:JRevision 30 dated April 15, 1985 - The profile j

technique for measurement of-type-2 skewed welds was incorporated- '

into the support procedure.

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-Six different methods'of documenting'the results-of' type-2~ skewed

weld inspections were permitted by procedure' at various times. These'. '

methods were: i

(1) HIR Hanger Inspection Report -

(2) CSC Component Support. Checklist

.

(3) MWDC- Multiple' Weld Data Card

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.(4) WICL Weld Inspection Checklist f

(5)' CSF/SWIR ' Component Support Fillet and Skewed Weld-

Inspection Report

(6) COT Construction ~ Operation. Traveler

The NRC inspector reviewed historical revisions of the ASME, Quality

' Assurance Procedures / Instructions Table'of Contents to verify the

accuracy of the developed chronology and also checked the methods

permitted by these procedures for documenting type-2 skewed welds. 'l

NRC inspection of this activity is complete. NRC inspection of

activities listed above also provide a basis for completion of

activities required by NRC Reference 05.a.01.01 and 05.a.01.02.

No violations or deviations were identified.

d. Document Control (ISAP VII.a.3)

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Du' ring t' his report period, the activities identified by NRC Reference

07.a.03.04 and the closeout of related external issues were inspected

as follows:

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ProcedureEvaluation-(NRCReference07.a'03.04) f

This ISAP required an evaluation of'the current CPSES document ]

control; procedures. The-issue coordinator' performed the evaluation,. j

l conducted and documented the results'of the interviews, and completed  !

a procedure checklist, which in total formed.the basis for the .

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evaluation. ,

.The; NRC' reviewed the procedure checklist and compared it to the. ..

requirements in Criterion VI of. Appendix B.to'10 CFR Part'50, and to.

the commitments'in the CPSES FSAR. The procedure checklist was found- .;

to address'the requirements'and commitments;concerning distribution  !

and control of documents affecting' quality. Utilizing this

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checklist, the NRC inspected the current controlling Procedure DCP-3, ^

Revision 19, "CPSES Document Control Program," to verify.that ERC had

implemented the checklist properly and that the procedure met the.

above requirements and commitments. -The procedure was found to

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properly contain.the following attributes: measures to assure that

all documents, and changes to documents,'were reviewed and approved.

~by. authorized personnel prior to distribution; and measures'to assure .

that all documents used for construction or. inspection, activities

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were maintained current and in a' controlled status; Additionally,. ,j

the procedure provided for: retrieval'or identification of superseded.

documents and for'an ' ongoing monitoring of' document control-

performance of all controlled doc'ument. files.by an independent.

monitoring team. 'No differences between'the.NRC and ERC~results were

noted in the completed checklists.

In. addition, the NRC inspected the implementation of DCP-3 by

requesting a sample'of 20 drawings and 10 procedures'from the .

document control center (DCC)'and one satellite. These documents. .

. were fourid to beLat their current ' revision with all design changes - i

entered when compared to the DCC master list of controlled documents.

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Thelimplementation'of tho independent monitoring team was inspected- l

by the NRC inspector by interviewing the head of the monitoring team,.  ;

. reviewing' monitoring'reportsLand executive summary reports, and -i

reviewing the report distribution which included the Vice-President,.

Engineering and Construction. Th'e monitoring team's reports  !

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indicated that-the' document control groups were achieving an error

-rate of less than 0.1%.

The NRC interviewed the ERC engineers responsible for 11-of the- :I

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32 populations.in ISAP VII.c to obtain similar information from the

. implementation of the VII.c ISAP. These engineers stated that of the

4,000 drawings utilized during inspection of .the 11 populations, they

found 6 document control errors or a 0.15%' error rate.

Based on"the' foregoing NRC inspections and the favorable comparison ,

with the results of the ERC inspections, this item has been properly l

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implemented. No violations or deviations were noted during the

inspection of this area of the document control program. j

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Closeout of Related External Issues

Two external issues related to document control were identified in l

ISAP VII.a.3. The issue of unauthorized procedures used for i

cold-springing of piping was addressed in ISAP V.e and was not

considered further in this ISAP. The issue that a " Controlled Copy"

stamp was improperly used by B&R ASME QA personnel was addressed.

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The NRC interviewed the current B&R document review supervisor who

stated that the document review group does not cuerontly use a

" Controlled Copy" stamp; however, this supervisor did state that for

a short time a stamp was used to mark drawings prior to presentation

to the Authorized Nuclear Inspector (ANI) for review. The NRC also

interviewed the B&R QE group supervisor that was involved when this

stamp was used. This individual indicated.that the stamp was used on

copies of small bore typicals before presentation to the ANI for

review. .1he practice was stopped and the stamp defaced after

issuance of $pecial Inspection Services (SIS) Report 355, which

documented the ANI's concern about the use of the stamp. Evidence of

the stamp dafacing was p'rcvided by a memo to the QA file dated

August 10, 1984, bearing an imprint:of the stamp before and after

defacing.' The corrective actions taken appear sufficient to prevent

recurrence. The improper use of the " Controlled Copy" stamp had been

previously determined by the NRC Technical Review Team (TRT) in c

SSER 11 to have had no adverse safety implications. No further NRC

inspection cf this item is planned.

4. Construction / Reinspection (ISAP VII.c) i

a. Establishing Populations

Section 4.3.1 of ISAP VII.c, Revision 1, required safety-related

hardware to be categorind into populations with homogenous work

activities (HWAs)' and associated quality characteristics (attributes) i

from which the required-random samples were selected. It also

required that a description and justification for homogeneity be

prepared for each population. Finally, each population was to have a

.

list of all final QC accepted safety-related itens. The CPRT 1

guidelines for establishing homogenous populations were contained in

the project procedure for ISAP VII.c, Procedure CPP-005, Revision 3.

This procedure required the discipline engineers to review equipment

lists from CPSES in order to subdivide the plant into homogeneous

populations that have been constructed using reasonable bemogeneous

work processes. The equipment reviewed, as specified in  !

paragraph 3.0 of ISAP VII.c, was limited to that which was safety

related, construction complete and final QC accepted. The equipment {

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.would be inspected for attributes selected after a complete ' review of l

engineering documents pertaining to the individual populations.

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The generation of a Population Description, Master Population list,

1 Population Items List, and a Work Process Memorandum are also

. procedurally required along with adequate control of subsequent j

revisions to each of these documents.

The NRC inspectors reviewed six ISAP VII.c populations '(i.e. , Large

Bore Supports. Rigid, Large Bore Supports Nonrigid, Small Bore Pipe  !

Supports, Pipe Welds / Material, Concrete Placement, and Electrical  !

Cable) to ensure that the homogenous populations were correct and i

'.

adequate and that ERC procedures, primarily CPP-005, were being l

adhered to. .

(1) Large Bore Supports Rigid (LBSR), Large Bore Supports Nonrigid -

(LBSN), and Small Bore Pipe Supports (SBPS)

The NRC inspector's review of these three populations was

performed concurrently because the population descriptions are

similar except for the population boundaries (large bore rigid,

large bore nonrigid, or small bore) and the Population Items

Lists were all derived from the same source document;.the Hanger

Installation Tracking System (HITS) list.

(a) Population Descriptions i

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/- NRC inspection verified that the systems listed by the CPRT

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for inclusion in these three populations were designated in

Section 17A of the FSAR as safety related, either Safety

{, Class 1, 2, or 3, and Seismic Category I. Cross checking

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from FSAR Table 17A to the three populations, however, by

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the NRC inspector identified that the Chilled Water System

(CWS) was omitted from the CPRT populations. Subsequent

review of the Population Items Lists did reveal that the

C CWS was included in the population; it was only

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inadvertently left off the Population Description lists of

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systems. The NRC inspector agreed that the listed

I population boundaries described all supports within the  !

definition of each population and that the Population

Descriptions adequately described those items which are not

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included within the scope of the populations. For example, ,

the Population Description for Small Bore Pipe Supports, l

,, Revision 1, dated July' 23, 1985, states that the population

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boundaries shall be small bore (2" NPS and smaller) pipe

supports located in Units 1 and 2 and common areas which

are seismic category I and of Safety Class 1, 2, or 3. The

scope of each population item shall include the support

cc nponents shown on the individual drawings. Exclusions

frw this population will be building structural members,

small bore piping, large bore pipe supports, and instrument ,

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piping and tubing supports. All CPRT sign-ohfs for revbiw' 3

.g cod approval as wall as' control and filing in CPRT records "

v} of the population' descriptions wersperformed per ,

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s(b) Master Population List ' ,L4

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NRC inspector r,etfew of the original Master Population List 1

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p and all. su'eseedint . revisions (one throtsh five) verified

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4' -that the ebovd thre4 populations were included on the list

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and that t'eview;Jarproval, and contpol of the documents are

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(c) Population Items Lirt

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Each of th'e three Population Items Lists were derived from

the HITS list. Th6 CPRT initially established the validi,ty

n and, accuracy of the HITS. list and then segregated out ths

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SDPS). To establish validity anA accuracy of the HITS

list, the CPRT randomly selected M B&R Hanger Location

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(BRHL) drawings out of the listed total of 2013 and <

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manually checked to see that all supports listed on the .

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3 J60 BRHLs were also listed on the HITS list. To verify th9 j

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accuracy of the support status listed on the' HITS list, '

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(. s . s60 supports were randomly selected from the 60 BRHLs and 3 t

,' their status individually verified by checking records in'

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v the various vaults and processing areas. This was require 0

because only final QC accepted pipe supports were to be

reinspected under the VII.c program. No discrepant

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conditions were detected by the CPRT.

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To assess validity and accuracy of the CPRT. verification of

!, . the HITS list, the hRC . inspector selected 10 out of the

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60 BRHLs that the CPRT had reviewed, and verified that all

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supports shown on the BRHLs.were included on the HITS list. .;

To further assess the HITS list, ten additional BRHLs not  !

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selected by the CPRT wera seiected by the NRC inspector and ,

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checked against the liITS list.foi sepport inclusion. These

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l 7 safety-related systems within the population were included

in the review. Finally, the NRC inspector reviewed the

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completion status'of 10 of the 60 supports that the CPRT

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had verified by researching records in the various vault

[,{l 3 < Jocations. No discrepancies were identified.

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(d) Work Process Memoranda

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< Pevision 3 to Procedure CPP-005 dated May 28, 1986,

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required all ISAP VII.c populations to have a Work Process

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Memorandum. This memorandum was to identify safety-related

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construction work processes and attributes that can be

reinspected and/or verified by document review. l

During this report period, the Work Process Memoranda

covered under this inspection were in the final draft

stages; therefore, they will be reviewed at a later date.

This is an open item pending completion of NRC review of ,

these Work Process Memoranda (445/8702-0-01; l

446/8702-0-01). ,

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(e) Revisions l

NRC review of all revisions to the Master Population List,

Population Descriptions, and the P7."slation Items List for

-the three populations revealed that the criteria of

Section 5.5 of Procedure CPP-005 were being adhered to as

far as sign-offs for review and approval, and control and

'

vaulting of the subsequent revisions.

No violations or deviations were identified.

(2) Pipe Welds / Material (PIWM)

This population was created by combining the two populations i

which were previously titled Large Bore Pipe Welds / Material  ;

(LBWM) and Small Bore Pipe Welds / Material (SBWM). In addition

to this combination, mechanical equipment, site-made, pressure

boundary welds were added to the PIWM population, and tubing

welds were organized into a separate populaticn (TUWM). At the

present time there is no documentation on file relative to the

basis-for these actions. This is an open item pending

development of such documentation and NRC review (445/8702-0-02;

446/8702-0-02).

(a) Population Description

NRC inspection verified that the systems listed by the CPRT

for inclusion in this population were designated in

Section 17A of the FSAR as safety related, either Safety

Class 1, 2, or 3, and Seismic Category I. In reviewing

Table 17A, however, it was observed by the NRC inspector

that the Boron Thermal Regeneration System, Combustible Gas

Control System, Post Accident Sample System, and the Plant

Gas System were not listed in the CPRT Population

Description, though they should have been. Subsequent

review of the Population Items List, however, verified that

these systems were included in the population; they were,

apparently, inadvertently left out of the Population

Description.

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The NRC~ inspector concurs with the population boundaries

and items not included in the population, as listed in the

Population Description.

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(b) Master Population List

NRC review of the original Master- Population List and all

subsequent revisions (one through five) verified that the

PIWM population was included on the list and that review,

approval, and control of the documents were per procedure.

(c) Population Items List

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The source document for the Population Items List was the

B&R Comanche Peak Craig Computer Tracking System (CCTS)

Report WEC-C-WE-REPORT issued June 12, 1985. This report ,

was a computer sort of all safety-related and QC accepted i

large and small bore pipe welds and instrument tubing welds

contained in the B&R computerized data base Welding

Engineering Component Master Report used for tracking

construction progress of site-made welds.

Attachment 6.3 of ERC Procedure CPP-005, Revision 3,

states, in part, "The Responsible QA/QC Discipline

Engineer . . . [p]rovides the basis for accepting the list  !

as valid." In addition, "The QA/QC Lead Discipline

Engineer and the QA/QC Engineering Supervisor review

Population Items List? to ensure that they are complete,

accurate, and consistent with the requirements of this

procedure." ERC stated on the Population Items List that

the following four steps were taken to validate the list:

1) A verification was made that the 591 site-made welds

listed on the ASME III N-5 Data Report Index for the

Unit 1 Auxiliary Feed Water system were on the

! Population Items List. 1

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2) A review was performed of field welds specified on all

26 Unit 1,BRP drawings for the Residual Heat Removal

j system and 26 randomly selected Unit 2 BRP drawings

l with respect to their inclusion in the

l WEC-C-WE-REPORT. All welds were found to be included.

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3) A review of 675 WDCs from several Unit 2 systems for

instrument piping welds was performed with respect to

i their inclusion in the WEC-C-WE-REPORT. All welds

were found to be included.  !

4) A review was performed of the construction completion

(C/I) status of welds listed in the Welding

Engineering Component Master Report. From this

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review, it was ascertained that most of the diesel

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' generator (Unit 1 and Unit-2) piping site-made welds '

had not been assigned a complete / incomplete status

runder the C/I column. . Accordingly, these welds.were

not . identified in WEC-C-WE-REPORT computer sort of ~

. complete,-QC accepted piping welds. These' welds were

. added to the WEC-C-WE-REPORTLto complete the'

Population' Items List.- 1

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The NRC inspector. initially. compared the systems listed in

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FSAR Table.17-A to the source document to assure

H . consistency. Next, the NRC inspector randomly selected-

,23 BRP drawings'for' Unit 1 and Unit 2'not previously:

selected by the CPRT and verified that the 416 site-made.

welds were included on the Population Items List. No

omissions'were noted.

To further. verify accuracy of'the CPRT approach, 10 of the

52 BRP drawings reitiewed by the CPRT were compared to the

source' document. .No discrepancies were found.

(d) : Work-Process Memorandum

See paragraph 4.a(1)(d) above.

.

(e) ' Revisions

NRC review of all revisions to the' Master Population List,

Population Descriptions, and the Population Items List for

the population revealed that the criteria of Section 5.5 of

Procedure CPP-005 were being' adhered to as far as sign-offs

for review and approval and. control'and filing in CPRT

records.of the subsequent revisions. j

No. violations or deviations were identified.

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(3) Concrete Placement (CONC)

The concrete placement. population contained 7617 concrete pours

identified on a computer' printout generated by B&R from concrete

pour cards.

-(a) -Population Descriptions

The'NRC. inspector. reviewed ERC document QA/QC-RT-328, I

Revision 0, " Population Description for Concrete

Placement." The population boundary included. all.

Category'1 concrete construction that had been completed

and approved as of August 1, 1985. The Category 1 l

structures were listed in Attachment A of the Population d

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Description. The NRC inspector verified that Attachment A

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agrees with the FSAR, Section 3.2.1.1.1, which also lists )

Category 1 structures. A subsequent review of the j

Population Items List (see below) verified that the list 1

contained concrete pours from each of the Category 1  !

structures listed in Attachment A. The NRC

inspector' concurred with the population boundary and the

items not included within the scope of the population. The

CPRT. review and approval as well as the filing in CPRT

records of the Population Description were performed per

Procedure CPP-005.

(b) Master Population List

NRC review of the Master Population List, Revision 5,

verified that the concrete placement population was

included on the list. Review, approval, and control of the

Master Population List was per Procedure CPP-005.

(c) Population Items List i

The NRC inspector reviewed ERC document QA/QC-RT-1628,

Revision 1, " Population Items List Concrete Placement."

The population source was a 254 page computer printout

generated from individual concrete pour cards by B&R. This

list included the concrete pour number, date poured and a

brief description of the area poured for each of the

7617 concrete pours in the population. According to this

document, the population list " . . . includes all

safety-related concrete pours in Unit 1, 2 and areas common

to both units."

Attachment 6.3 of ERC Proceduro CPP-005, Revision 3,

states, in part, "The Responsible QA/QC Discipline

Engineer . . . [p]rovides the basis for accepting the list

as valid." In addition, "The QA/QC Lead Discipline

Engineer and the QA/QC Engineering Supervisor review

Population Items Lists to ensure that they are complete,

accurate, and consistent with the requirements of this

procedure." ERC stated on the Population Items List that

the following three steps were taken to validate the list:

1) Twenty arbitrarily chosen pour numbers identified on

B&R drawings were found to be on the population list.

2) An arbitrary selection of concrete pours from

Inspection Report Logs were reviewed against the

! population list and no discrepancies were identified.

3) A review of the population list confirmed that no time

gaps were apparent in the pour dates.

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.The NRC' inspector reviewed the steps taken by ERC to-

validate the population list fo'r ' concrete placement.' Only

step.1 above was documented. A handwritten, unsign'ed and

undated' memo describes the 20 concrete. pours (10 from the

random sample and 10 from the safe shutdown sample).that~

were verified by ERC to be on the population list. The

20 concrete pours selected by ERC for verification of the

completeness of the population list represent only

0.26. percent of the total population of'7617. The extent

of'the ERC review is. inadequate to ensure accuracy and'

.

' completeness of the Population Items' List. .The NRC

inspector. verified that the 20 concrete pours' selected by-

ERC were on the population' list.

In' addition,.the NRC inspector prepared a randomly se.lected

, list of 134 concrete pours from 17 B&R drawings'and

compared this list with the Population Items List to.

determine if the 134 concrete pours were included. The

following discrepancies were discovered:

'1) Pour Nos. 205-9810-039 through 205-9810-056 are shown

as block-out type pours in the east diesel generator

' foundation, Unit 2,.on Drawing SSB-20655, Sheet.1,

Revision 5. Pour Nos. 205-9810-040 and'205-9810-048

through 205-9810-056 were not on the Population. Items

List and no corresponding pour cards'could be obtained

in the TV Electric records center. Pour

Nos. 205-9810-039 and .205-9810-041 through-

205-9810-047 were assigned on drawings at least twice

and are shown, for example, on Drawings SSB-20605,

Sheet 1, Revision 7, and'SSB-20618, Sheet 1,

Revision 2, to be concrete curbs, removable slabs,

etc. ; not block-outs. Pour Nos. 205-9810-039 and

205-9810-041 through 205-9810-047 were on the

Population Items List. They did not, however,

represent the block-out pours in the diesel generator

foundation as determined by checking the' concrete pour

cards. The NRC inspector verified by field

inspections that the block-out pours had been

installed.

2) Pour No. 205-4822-003 is shown as a shielding wall for.

the Primary Sampling room on Drawings SSB-20605,

Sheet 4A, Revision 0, and SSB-20605, Sheet 4,

Revision 0. This pour number was not on the

j Population Items List. A pour card for this pour was

located in the TV Electric Records Center. The NRC

inspector verified by_ field inspection that the

shielding wall had been installed.

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The above discrepancies ' indicate that the Population It' mse

List .is not entirely complete and accurate and does not- <

include ". . .~all safety-related concrete pours in

LN t 1, 2.and areas common to both units," as stated. .The  ;

ERC review of the- Population -Items List to ensure accuracy ' i

This:is a deviation'

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and completeness was inadequate.  ;

(445/8702-D-03;-446/8702-D-03). i

(d) Work Process Memorandum'

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See paragraph 4.a(1)(d)'above. l

(e)' Revision's

NRC review of all revisions to the Master Population' List,

Population Descriptions, and-the. Population Items' List for i

the population revealed that the criteria.of Section 5.5 of

Procedure CPP-005 were being adhered to as'far as sign-offs

for review and approval, and control and filing in CPRT q

Records of the subsequent revisions.

No violations or deviations other than as'discu sed in (c):

above were identified.

(4) ' Electrical Populations

.The NRC inspector reviewed the Population Items List

documentation for each of the electrical. populations to

determine which sources were used to develop the population and

the basis for the CPRT determination that the developed

population.was accurate.

The NRC inspector found that the conduit, cable, cable tray,

electrical equipment and NIS cable termination (CDUT, CABL,

CATY, EEIN, and NIST) population lists were generated using the

TU Electric Electrical. Management System (EMS) as a source. EMS

~

-was a computerized cable and raceway schedule developed by site

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personnel'to track'the status of Unit 1, Unit 2, and Common ,

cables and raceways. Cable and raceway' changes authorized by I

design' change authorizations (DCAs) were entered into EMS on a

daily basis. . The EMS then provided a printout of these daily

changes on a Daily Activities Report. Since EMS was neither a

required permanent plant

'

.the previous EMS revision. document

s and nor controlled

Daily Activity by procedures,

Reports had not

been retained as permanent plant records; however, the NRC

inspector observed that' copies of the EMS printouts which had l

been used by ERC for population list development, were retained l

in the QA/QC Review Team files in the CPRT document control '

center.

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The electrical cable.(CABL) population was. selected for a more

p' - detailed NRCfinspection to evaluate the implementation of the-

appropriate procedures for establishing and accepting the

'

_ population.

(a)l Population Description.

1, The NRC inspector's review of the Population Description

.

for cables identified that the population was to include.

'

-all Class 1E', safety-related power, control and instrument l

cables. - The population boundary for samples selected.for '

reinspection / documentation reviews was' restricted.to those

cables which had been installed, terminated on both. ends

and QC accepted. Excluded from the population were

electrical conductor seal assemblies, NIS cable connectors,

and unscheduled lighting (except.for sep'aration barrier

material inspections). These three groups were. excluded-

from the cable population-because they were included in <

,

other populations. Based'on his understanding of the >

systems involved, the NRC inspector concurred that the

population boundary and the items not included within.'the

scope of the population represented a valid. population of

involved electrical cable. The CPRT! review and approval as H"

well as the filing of the Population Description was

performed per Procedure CPP-005.

(b) Master Population List

'

NRC' review of the Master Population' List, Revision 5,

verified that the electrical cable population was included

on'the list.. Review, approval, and control of the Master-

Population List was per Procedure CPP-005.

'

(c) Population: Items List.

Procedure CPP-005 required the responsible QA/QC Discipline'

Engineer to prepare a list of all applicable items ~within

the population out1.ined in the Population Description along

with the. method of development. This' list was then to be) ,

reviewed and approved by the QA/QC Engineering Supervisor- '

who would forward it to the QA/QC RecordsfAdministrator.

The NRC inspector verified that a comparison of the items l

documented in the Cable Population Items List to the items

required by CPP-005 was performed by the QA/QC Discipline

r Engineer. The list was divided into three parts:

. Population List Source; Basis for Accepting the List; and

J Basis for Accepting any Additional Items. The NRC

inspector determined that this met the requirements of.

CPP-005.

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The Population List Source contained 'the-listing and'

. description of the documents used to, develop the listing of- !

. applicable electrical cables'. The sources referenced were  !

E

the EMS cable report (ELE SAFETY RPT) dated June 17, 1985,

'

and'the Gibbs & Hill (G&H). Lighting Panel. Schedule, ~ .

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Drawings 2323-El-0942-01'through -05-and.E2-0942-01 through

-03. NRC inspector review'of these documents disclosed'

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that Drawing 2323-E2-0942-03 did not exist. The NRC.

inspector then reviewed the file applicable to the Basis

for Accepting the List and questioned how the EMS was-

validated by the CPRT as'a'completeLsource of applicable-

electrical. cables. The NRC inspector'wasLinformed that.the

.QA/QC Discipline Engineer responsible for the cable '

population had selected 30~ cables each from the raceway.

schedules for Unit 1 and Unit 2 (2323-El-1700-

'o and 2323-E2-1700) and.then. compared these' cables to the EMS

-listing he had used in order to verify the validity of the

source documents.: The NRC inspector also' verified, by a 1

review of the CPRT files, that the'QA/QC Engineering. . .

Supervisor had approved and forwarded the list as required... '

-The NRC inspector determined, based on the above, that the

requirements of CPP-005 had been fulfilled in establishing

this population.

In an effort to separately evaluate the acceptability of.

the cable population (which contained over 14,000 cables)

the NRC inspector chose an arbitrary sample of affected:

cables. Between 1 and 6 cables from each safety-related

plant system from the Unit 1 and the Unit 2 raceway

schedules in the plant permanent records vault and

14 cables from the unscheduled lighting panel drawings were

selected. This resulted in a sample which contained.

125 cables from 55 systems in Unit 1 and 122 cables from

51 systems in Unit 2. These cables were then" compared to

the CPRT's cable population list to provide assurance that

the population-list used by ERC'was complete. The

comparison of these -lists produced the following findings:

1) The list of Essential and Emergency Lighting cables

was not in the, file,

,

2)- Pages 813 and 814 of the EMS listing were missing'from

the file,

3) Cable E0000425 was not' included in the file list, and

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4) Cable E0135036.was shown as EG135036 in the file list.

The NRC inspector then determined that: a copy of the list

of Essential. and Emergency Lighting cables was available in '

the electrical conduit population files; the missing EMS

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'pages were available from working copies; DCAs 18,100

and 18,547 authorized a designation change for cable  !

E0000425:to A0000425; 'and the improper separation train

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' designation _(G vs. 0) for cable E0135036 was a. data entry

error.', Since;the NRC's inspection showed that the cable

population.lis.t developed by the CPRT'from.the EMS. appeared

to be more. complete than the Cable and Raceway Schedule J

from the permanent plant record vault, the NRC inspector )

found that the population list was' acceptable. . However,- 1

"

the condition of the record files not being' complete as-

evidenced by 1) and 2) above is a deviation from ERC ,

Procedure CPP-004, " Project Working Files," Revision 2,-  !

dated D.ecember:17,1985 (445/8702-D-04; 446/8702-D-04). -

(d). Work Process Memorandum

See paragraph 4.a(1)(d) above.

(e) ' Revisions j

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NRC review of all revisions to the Master Population List, .;

Population Descriptions,.and the Population Items List for-

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the population revealed that the' criteria of Section 5.5 of 1

Procedure.CPP-005 were being adhered to as far as sign-offs

for review and approval, and control and filing in CPRT

records of the subsequent revisions.

No violations or deviations other than as discussed in (c),

above, were identified,

b. Reinspection of HVAC Equipment Installation (HVIN)

Status of CPRT Activity

A total of 181 HVAC equipment packages were randomly selected and

inspected from a population of 604 packages representing Units 1, i

2 and common. A total of 331 DRs were written with 187 determined to

be valid. ERC has completed all planned HVAC equipment installation

reinspections.

Status of NRC Inspection Activity

The NRC inspector reviewed the HVIN population with respect to HVAC .!

fire dampers and their inclusion in the population. The NRC 1

inspector identified that approximately 30 percent of the_ random and W

engineered samples consisted of fire dampers that were statused as j

" Abandoned In Place"; i.e., nonsafety related. This raised a j

question with respect to the inclusion of nonsafety-related equipment ]

in the HVIN population. This was discussed with the population

engineer who provided the following information. Due to problems

that were identified with fire dampers which limited their ability to

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function correctly, a study.was performed (GTN-60298 dated July,27, l

1984) that concluded certain fire dampers could be " Abandoned In l

Place" and would not be required for a safe shutdown. These dampers j

were included in the HVIN population as an accessory connection only 1

and were inspected for proper mounting and bolting, but not l

operability, to assure that these dampers would not interfere with d

operation of the HVAC system at some later date. ERC issued letter

QA/QC-RT-5584 dated February 2, 1987, to the population file, j

providing this'information. The NRC inspector verified the validity l

of the information through review of the study and supporting

^

documentation and found this to be consistent with ISAP VII.c

regarding Populations Items List development.

The NRC inspector has previously witnessed four inspections and

performed five inspections with no further inspection activity

planned for this population. i

No violations or deviations were identified.

.5. ISAP Sample Selection Process

The purpose of this NRC inspection was to determine whether the methods

used to select items and related documentation for reinspection or review-

was performed in accordance with the requirements of the CPRT Program.

Plan, Appendix D, Revisions 0 and 1, "CPRT Sampling Policy Applications

and Guidelines." Appendix 0 prescribes the various applications of

sampling within the CPRT program and defines guidelines for selecting

samples whenever random sampling techniques are used in ISAPs and Design

Specific Action Plans (DSAPs). This inspection was restricted to the

review of ISAP sample selections. The scope of the inspection covered

electrical, mechanical and piping, QA/QC, and the Quality of Construction

ISAPs. The inocerational and testing ISAP sample selection was reviewed

in a previor "^9pect!.m with results documented in NRC Region IV  !

Inspection Report 50-445/85-18; 50-446/8S-15. Another activity previously

inspected by the NRC for compliance to Appendix D was the ERC Overview

Inspection Program's sample selection. Results of this inspection were

' documented in NRC Region IV Inspection Report 50-445/86-22; 50-446/86-20. &

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The NRC approach used to review ISAP documentation and the inspection of

samples selected was: (1) to review the requirements identified in

Appendix 0 and the applicable procedures, and (2) to verify implementation

of the sample selection process by comparing the samples selected to the

controlling commitments. Samples were then reviewed to assure that:

random number selection and item number calculations were correct; items

identified for inspection had a valid sample number and a random number l

assignment; errors in the selection of items for inspection had been  ;

resolved; departures from the sampling process had been identified; '

populations were clearly defined and segregated; minimum sample size

criteria were correct and documented and enlargement of sample size was

made, as necessary, to assure that the minimum sample size would be

achieved for all attributes; expansion of sample size, based on identified i

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hardware deficiencies,-conformed to requirements; and the sample selection

process was suitably documented to provide an auditable trail. I

Of the 19 external source issue ISAPs considered for inspection,

5 completed and 1 in process ISAP were inspected. From ISAP VII.c, 5 of

31 in process populations were inspected. The following are the results

of this NRC inspection. j

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a. QA/QC ISAPs

(1) ISAP VII.a.2: Nonconformance and Corrective Action (inprocess).

This ISAP contained six populations, each requiring a separate

sample selection that would provide a.95/5 screen. (The

95/5 screen or sampling plan provides a 95% confidence that not

more than a 5% deficiency rate exists in the sampled

population.) Of the six populations, the sample selection for

NCRs covering the years 1975 to 1977 was reviewed by the NRC i

inspector. Twenty-one of the sixty-three selected samples were i

examined. No errors were noted in random number calculations or

sample item identification from the. population item list. It

was determined, based on the NRC inspection, that the NCR sample [

selection conforrned to Appendix D requirements.

(2) ISAP VII.b.2: Valve Disassembly (complete).

During the NRC's inspection of VII.b.2', no errors in the 95/5

sampling plan were found. The NRC inspector reviewed 21 of the

111 sample selections and found them to conform to Appendix D, 3

ERC's implementing Procedure QAI-002, Revision 2, " Sample  ;

Selection"; and CPP-006, " Sample Selection." Prior to '

completion and issuance of the VII,b.2 Results Report on

March 19, 1986, ERC's QA/QC surveillance group and the Results

Report Review Committee's (RRRC) review of sample selection

identified errors in the selection process. Corrective action

by the ISAP issue coordinator included revising the Random

Sample Identification List and performing additional hardware  !

reinspections.

b. Electrical ISAPs

(1) ISAP I.a.1: Heat Shrinkable Insulation Sleeves (Revision 1 of ,

the Results Report issued December 30., 1986). )

i

The NRC inspected 13 of the 111 samples selected for this ISAP. j

From the CPRT reinspection of the initial 60 items randomly l

selected, providing a 95/5 sampling plan, one was considered to I

be a defect requiring sample expansion. As required by

Appendix D of the CPRT Program Plan, the sample was expanded by J

an additional 35 randomly selected items. Four of the l

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additional thirty-five samples were found.to be_ invalid and were

deleted because they represented locations that did not use heat

shrinkable insulation sleeves. To reach the required expanded

sample size, seven additional items were selected. Thus, the

total valid samples selected by CPRT for reinspection was 98;

however, during implementation of ISAP I.a.2, " Inspection

! 3 Reports on Butt Splices," 146 items were discovered that had

been inadvertently excluded from the original heat-shrinkable

insulation sleeve population. Proportional sampling was used on

this additional population by selecting 12 of the 146. The CPRT

advisor on engineering statistics approved the use of this

'

proportional sampling which was not addressed in Appendix D of

the CPRT Program Plan.

Due to errors in the calculation of the random numbers, one item

that should have been inspected in the additional 35 items

selected had been'omitted. This item was, however, inspected .

and is referenced in the working files as the " missed sample." i

With the' inspection of the " missed sample," the total number of

valid randomly selected items inspected was brought to 111 (the-

initial 98, 12 from proportional sampling, and the one " missed

sample").

Based on the review of sample selection documentation,: detailed j

inspection of 13 sample selections, and a review of other

'

sampling activities associated with this ISAP, the NRC inspector

determined that the I.a.1 sample selection process conformed to  !

Appendix D.

(2) ISAP I.a.4: Agreement Between Drawings and Field Terminations

(Revision 2 of the Results Report. issued July 23,1986).

Of all the ISAPs and VII.c populations using random sampling,

this ISAP used a 95/1 screen instead of 95/5. Both screening

techniques are addressed in Appendix D,. Table 1. As with

ISAP I.a.1, additional population items were discovered during

ISAP implementation. Proportional sampling was again used and

approved by the CPRT engineering statistics advisor. Based on a .

review of sample selection documentation and verifying in detail l

the selection process (38 out of 383 selected items), the NRC ]

inspector determined that I.a.4 sampling conformed to i

Appendix D. j

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c. Mechanical ISAPs:

(1) ISAP V.a: Inspection for Certain Types of Skewed Welds in NF

Supports (Results Report issued October 22,1986).

1

The NRC inspector examined in detail 16 of the 60 samples 1

selected and found sample selection conformed to Appendix D;

however, three documentation inconsistencies were noted between .

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the Random Sample Identification List (RSIL) and ERC Procedure

QI-006, Attachment 6.5, Revision 2. Listed on Attachment 6.5

were the 60 hangers inspected by ERC as taken from the RSIL.

The inconsistency was not with the actual unique hanger number,

but with the alphanumeric suffix character which~ indicates the

type of hanger; i.e.,.A-anchor, S-spring, R-rigid, or K-snubber. !

Three hanger types were incorrectly coded as "K" instead'of "R".

The suffix characters also identify building, elevation, and

code class. From reviewing the actual packages inspected, the

NRC inspector verified that the~ correct hangers were selected

and inspected. The ISAP V.a issue coordinator is in the process

of correcting the documentation inconsistencies identified by

the NRC.

(2) ISAP'V.d: Plug Welds (Revision 1 of the Results Report issued

December 18,1986). '

This ISAP contained four populations. Sample selection for each

population was based on the 95/5 screen. The NRC inspector  !

examined 67 of the 250 sample selections from the 4 populations.

Eleven errors were found by the NRC inspector involving

calculation of the random number which resulted in a different

/ random item being selected. It should be noted that prior to-

the issuance of the Results Report (Revision 1), the statistical

advisor reviewed 100% of this ISAP's sample selection. . Based on

'

.

this review, 14 of the 250 samples had been identified with the

same type errors that the NRC inspector had identified. These

14 errors included the 11 errors found by this NRC inspection.

The scope of the statistical advisor's review of sample

selection is further discussed in paragraph e. below. Based on

results obtained from ERC inspections, plug weld testing, and

bounding analysis performed by Ebasco, the statistical advisor

determined the errors found in the sample selection did not

impact inspection results nor was there a need.to reopen the

inspection program. Since the errors only resulted in a

different item being randomly selected and inspected and the

statistical advisor determined that the sampling process itself

was not compromised, it was not necessary for these errors to be

, corrected. This conclusion was supported by referenced

documentation which was found in the Results Report working

'

file.

d. ISAP VII.c: Construction Reinspection / Documentation Review Plan

(inprocess).

i

This ISAP is unique because the VII.c work activities are divided j

into 32 homogenous populations. On completion of all work 1

activities, a summary Results Report will be issued. Details of l

reinspections and document reviews performed will be addressed as

appendices to the summary Results Report. At the time of this NRC

inspection, the Results Report and associated appendices were in

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their draft form and subject to various CPRT inprocess reviews; e.g., l

RRRC, ERC engineering assurance and QA. J

Thirty-one of the thirty-two populations used statistical random g

sample selection with the 95/5 screen (one population had less than 1

60 items, field fabricated tanks, thus all items were included in the '4

sample). The NRC inspector examined sample selections for'5 of the

31 populations that used statistical sampling. From these

5 populations, 154 of the 502 sample items selected were inspected

for compliance to Appendix D of the CPRT Program Plan and ERC

Procedure CPP-006, Revision 3, " Sample Selection." Procedure CPP-006

was more prescriptive than Appendix D in-that.it provided ERC

personnel with details for implementing the requirements-for. sample i

selection. The five populations inspected by the NRC were: Cable

Tray, Nuclear Instrument System Cable Termination, Electrical

Equipment Installation, Instrumentation Equipment Installation, and

Large Bore Piping Configuration.

Typical errors encountered were calculation of random sample number;  ;

use of duplicate random numbers; incorrect population item used;

deviations from Appendix D not adequately documented; selection of

items related to safe shutdown; and numbering of inspection work

packages. Problems encountered that were not deviations from

Appendix D or CPP-006 but made verification of sample selection

difficult were: inadequate guidance for proportional sampling which

was necessary when increases in population sizes were required;

method of numbering Population Item Lists; and inadequate guidance

for the resolution of problems encountered during sample selection.

These errors and problems are discussed below.

e. Sample Selection Review by the SRT

The statistical advisor to the CPRT has conducted and is continuing

to conduct reviews of ISAP sample selection. By direction of the

SRT, the statistical advisor was required to conduct reviews of those

ISAPs and VII.c. populations using sample selection to assure

conformance to Appendix D. This requirement was delineated in CPRT

memorandum CPRT-138 dated December 3, 1985, which the statistical

advisor stated is being implemented by a 100% review of the sample

selection process for all ISAPs and VII.c populations utilizing

statistical sampling. To date, the statistical advisor has reviewed

100% of the sample selection process for 9 of 22 ISAPs and 19 of the 1

31 VII.c. populations using statistical sampling. '

A checklist was developed and used by the statistical advisor to

perform the reviews and to document the findings and actions

required. On completion of the review, the issue coordinator or

population engineer was given a copy of the checklist. Each finding

and the actions required were discussed with the audited group. A

formal tracking mechanism to verify completion of actions required

had not, as yet, been developed or implemented. From interviews with

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the statistical advisor, a formal procedure and tracking system will

be developed and implemented to assure actions required are completed

in a timely manner. This activity will be.followed by the NRC as an 1

open item (445/8702-0-05; 446/8702-0-05).

Each of the errors and problems found by the NRC inspector had been l

identified and documented by the statistical advisor.

To assure that no Results Report is published with open sample i

selection errors, the'RRRC revised its working file check list on

February 17, 1987, to require all open sampling errors identified

against a Results Report be resolved prior to.RRRC approval of the

working file and submittal of the Results Report to the SRT.

f. ERC's Review of ISAP and VII.c Sample Selection

(1) Engineering Assurance

ERC has established an engineering assurance (EA) group to i

perform final review and assembly of records and supporting l

documentation (working file) required for ISAP VII.c prior to j

turnover to the CPRT central file. This effort was governed by i

Procedure CPP-026, Revision 0, " Final Review of ISAP VII.c

Working Files." EA had performed an initial review of VII.c

sample selection during July and August 1986. A written ,

checklist was used to direct the review and document findings i

for follow-up. Several items remain open. It should be noted

that during the EA initial review of sample selection not all

sample selections were finalized. Work was still in process to  ;

develop and complete.some populations and perform sample  ;

selections. The final review by EA for sample selection was f

scheduled to start in February 1987, but was contingent on

Population Random Selection Identification Lists being completed j

and approved. j

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(2) ERC C a ity Assurance i

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The QA surveillance group has performed 19 surveillances of in l

process ISAP activities. These surveillances, performed j

immediately prior to Result Report submittal to the SRT, were to 1

determine that Results Reports appropriately addressed the i

respective action plan. For those ISAPs using sample selection, 4

the surveillances included an in depth review of sample

selection methodology and results. The purpose of thr sample

selection review was to verify the sample selection process

methodology and results were adequately documented and conformed

to the requirements of Appendix D of the CPRT Program Plan.

With respect to ISAP VII.C, QA surveillance performed a review

of sample selection which included population description and

selection methodology for first and second samples taken,

proportional sampling, and extended sampling. As described

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Jabove,'EA'will perform a 100 percent review of VII.C sample

selection' activities.

.In addition tdLQA' surveillance off1 SAP sample selection, the ERC.

QA audit group;has performed two programmatic audits :of the

'

sampling process as documented in ERC audit reports ERC-86-05.- i

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and ERC-86-06. LNo findings were.noted in~those audit reports, a

< g. - Overview Quality Team (0QT)

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From interviews with the 0QT, the NRC determined that.the.0QT j

has not planned any reviews of ISAP- sample selection., ' The

review responsibility for ISAP sample' selection had been ]"

,

j

assigned to the CPRT statistical advisor and the RRRC. The

sample selection for several:ISAPs have been examined by the

0QT.' These were'notfin depth reviews such as those conducted by

the.ERC_QA surveillance group or the CPRT statistical advisor. 1

Rather; the 0QT reviews were to determine' that statements.made

in the.ISAP Results Reports with respectato sample" selection l

methodology and results'were. traceable to supporting j

documentation in the'ISAP working file. .The 0QT: compared j

Results Report statements;to the working _ file'to verify that th'e H

documentation existed with regard to population definition, 1

population size,. sample selection methodology, results of sample

selection, and the justification for additional and/or expansion

of sample selection. 3

.

.

1

In summary, of the 50 action plans using sample selection (19 external. 1

issue ISAPs and 31 VII.c populations),.the NRC inspected 11 for j

conformance to Appendix D. From the 11 action plans, 330 of the

1480 sample selections.were examined for errors by the NRC < inspector. . Fo

those action plans-inspected, the sample selection efforts were found to s

conform to Appendix D. Those errors in the sampling process that were

identified by the NRC inspector had also been identified by the CPRT- f

statistical advisor and action to correct or disposition the errors had

either been taken or was.being taken.

At present, the statistical advisor does not have a system to verify the

completion of action required to correct or disposition identified errors.

j

j

A commitment has been made to develop and implement such a system. .This _l

commitment will be followed as a NRC open item, as discussed in I

paragraph 5.e. above.

No violations or deviations were identified. I

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6. Exit Interview

Exit interviews were conducted February 10, 1987, and March 3, 1987, with

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the applicant's representatives identified in paragraph 1 of Appendix B of

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this report. During these interviews, the NRC inspectors summarized the

scope and findings of the inspection. The applicant acknowledged the

findings. l

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