IR 05000483/1989002

Insp Rept 50-483/89-02 on 890124-0215.Violations Noted. Major Areas Inspected:Environ Qualification of Electrical Equipment within Scope of 10CFR50.49 (Modules 30703 & 92701)

ML20235U660
Person / Time
Site:	Callaway
Issue date:	03/02/1989
From:	Gardner R, Kopp M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20235U653	List: IR 05000483/1989002 ML20235U650
References
50-483-89-02, 50-483-89-2, NUDOCS 8903090313
Download: ML20235U660 (4)

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U.S. NUCLEAR REGULATORY C0f411SSION

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REGION III J l

Report No. 50-483/89002(DRS)

l Docket flo. 50-483 License No. NPF-30 Licensee: Union Electric Company Post Office Box 149 - Mail Code 400 St. Louis, MO 63166 Facility Name: Callaway Nuclear Plant Inspection At: Callaway Site, Steedman, M0 65077 Inspection Conducted: January 24 through February 15, 1989 l Inspector: M. J. Kopp 3 7

hf Approved By: [t[N Ronald N. Gardner, Chief Da te Plant Systems Section

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Inspection Summary  ;

Inspection on January 24 throuch February 15, 1989 (Report No. 50-483/89002(DRS))

Areas Inspected: Routine announced safety inspection of previously identified inspection findings regarding the environmental qualification of electrical equipment within the scope of 10 CFR 50.49 (Modules 30703 and 92701).

Results: Within the area inspected, one violation was identified regarding environmental qualification deficiencies. These deficiencies are sumarized below:

I tem fl Violations Report Section 50-483/89002-01A Inadequate EQ documentation for 2.a. b Marathon 1600 and Kulka terminal block /89002-01B Deficiencies regarding Raychem splices in EQ application kD

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DETAILS Persons Contacted Union Electric Company

• J. Blosser, Plant Manager, Callaway

+* Campbell, Nuclear Engineering Manager

• J. Laux, Quality Assurance Manager

• J. Peevy, Assistant Manager, Technical Services

• W. Robinson, Assistant Manager, Operations and Maintenance

+*J. McGraw, Superintendent, Design Control

• G. Czeschin, Superintendent, Planning and Scheduling

• R. Butler, Supervising Engineer, Quality Assurance

+*D. Wingbermuehle, Supervising Engineer, EQ Materials

• C. Slizewski, Supervising Engineer, Quality Assurance R. Hamblen, Supervising Engineer

• S. Merciel, Engineer, EQ

• E. Kahl, Engineer, Licensing

• G. Sellmeyer, Engineer

• S. Petzel, Engineer R. Haines, Engineer B. Yates, Engineer, Licensing Nuclear Regulatory Commission (NRC)

• B. Little, Senior Resident Inspector

• C. Brown, Resident Inspector

• Denotes those attending interim plant exit on January 27, 198 + Denotes those participating in final exit on February 15, 198 . Previously Identified Findings (Module 92701) LClosed)UnresolvedItem(483/87015-02(DRS)): This item addressed the lack of insulation resistance measurements taken during the Environmental Qualification (EQ) testing of Marathon 1600 terminal blocks. During the inspection, the inspector noted that a 12 amp fuse had been connected to the 132V circuit; however, no insulation resistance measurements were recorded. The inspector also noted that the 12 amp fuse in the 132V circuit failed late into the LOCA tes The inspector concluded that the licensee's EQ documentation did not support qualification of the Marathon 1600 terminal blocks for 120V application CFR 50.49, Paragraphs (f) and (g) require electrical equipment important to safety to be qualified by test and/or analysis. The licensee's failure to demonstrate qualification through adequate EQ test documentation is considered a violation of 10 CFR 50.49 (50-483/89002-01A(DRS)). The licensee's corrective actions for the above violation were reviewed during this inspection. The licensee

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replaced the terminations to Marathon 1600 terminal blocks with qualified Raychem splices. Additional data was added to the EQ binder to reflect proper evidence of qualification. No further concerns were identifie b. (Closed) Unresolved Item (50-483/887015-03(DRS)): This item addressed insufficient evidence to demonstrate qualification of Kulka terminal blocks for 480 VAC and 120 VAC applications during accident conditions. The inspector noted that a 10 ma fuse, used to monitor leakage currents, had failed during EQ testing. The circuit voltage then had to be reduced from 600 VAC to 370 VAC to keep the fuse from failing again. The inspector also determined that the licensee's EQ file did not include appropriate details of the test plan, method of measuring insulation resistance, and justifications for low insulation resistance reading Further investigation determined that due to failures, the Kulka terminal blocks had been disconnected from their voltage source after seven hours into the tes CFR 50.49, Paragraphs (f) and (g) require electrical equipment important to safety to be qualified by test and/or analysis. The )

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licensee's failure to demonstrate qualification through adequate 1 l EQ test documentation is considered a violation of 10 CFR 50.49 (50-483/89002-01A.(DRS)). Subsequent to the inspection, the NRC determined that qualification of Kulka terminal blocks was demonstrated !

by Bunker Ramo Report No. 123-2222 and Conax Report No. IP5675. The licensee's corrective actions for the above violation were reviewed during this inspection. The licensee revised the EQ file to include Conax Report No. IP5675. No further concerns were identifie c. (Closed) Unresolved Item (50-483/880*9-02(DRP)): This item addressed deficient Raychem splices installed in EQ circuits. As a result of licensee reviews and field verifications, the licensee identified Raychem splices installed in configurations which were not enveloped by the EQ test on file at Callaway. Deficiencies were identified in the following areas:

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Incorrect installation

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Missing shims

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Heatshrink tubing missing

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Minimum bend radius violated

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Incorrect sizing of heatshrink

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Improper shrinking License Event Report (LER)88-013, Revision 1, dated January 3, 1989, was written by the licensee and addressed deficiencies, corrective acticns and root cause CFR 50.49, Paragraphs (f) and (g) require electrical equipment important to safety to be qualified by test and/or analysis. The licensee's failure to install Raychem splices in EQ circuits in a configuration tested by the EQ test report is considered a violation of 10 CFR 50.49 (50-483/89002-01B(DRS)). j l

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During this inspection, the inspector reviewed the licensee's corrective actions for the above violation. The licensee replaced deficient Raychem splices, performed engineering and operability l analysis, added data to EQ binders to reflect qualification, revised i installation and inspection procedures and retrained personnel. No I further concerns were identifie ) Thomas and Betts Connectors (T&B)

As a result of previous discussions with Region III personnel, the licensee

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was made aware of a concern with the qualification of T&B wire connectors used in Limitorque dual voltage motor actuators. The concern developed i from the failure of the connectors during a recent EQ test conducted by Illinois Power Company. The connectors failed when subjected to moisture, l after having been irradiated and thermally aged. Consequently, the connectors failed to demonstrate a 40 year qualified life. The licensee i'

informed the inspector that their review did not identify any actuators with installed T&B connectors which would be required to perform a safety function during 100% relative humidity accident condition I However, based upon the Illinois Power Company test, the licensee revised the qualified life of T&B connectors installed in Limitorque actuators at Callaway. The licensee initiated EQ Change Notice No. 89-17, dated January 31, 1989, which revised the qualified life from 40 years to 26.54 year i l

No violations cf NRC requirements were identifie ) Exit Interview ,

The Region III inspector met with the licensee's representatives (denoted in Paragraph 1) during an interim exit on January 27,1989, and discussed the findings by phone at the conclusion of the inspection on February 15, 1989. The inspector summarized the purpose and findings of j the inspection and the licensee acknowledged this information. The '

licensee did not identify any documents / processes reviewed during the j inspection as proprietar .

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