IR 05000413/1985011

Insp Repts 50-413/85-11 & 50-414/85-09 on 850326-29.No Violation or Deviation Noted.Major Areas Inspected:Const Progress,Housekeeping,Preservice Insp & Insp & Inservice Testing of Pumps & Valves

ML20127L711
Person / Time
Site:	Catawba
Issue date:	04/08/1985
From:	Blake J, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20127L682	List: IR 05000413/1985011 ML20127L678
References
50-413-85-11, 50-414-85-09, 50-414-85-9, NUDOCS 8505230063
Download: ML20127L711 (13)

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. UNITED STATES -

[ pet [Erog '

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- NUCLEAR REGULATORY COMMISSION

.p 'n - REGION II

.g Jj 101 MARIETTA STREET, * g ATLANTA, GEORGI A 30323

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Report Nos.: 50-413/85-11 and 50-414/85-09

. Licensee: Duke Power Company

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422 South Church Street Charlotte, NC 28242

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Docket.Nos.:' 50-413 and 50-414' License Nos.: NPF-35 and CPPR-117 s

Facility Name: Catawb Inspection Con . ch 26 - 29, 1985

. Inspect r: */ f W. P rge .E Date Signed v Appro ed by: Y!b/Lar

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der J ETake, Section Chief ITate Signed

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En ne ing Branch

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.D ist n of Reactor Safety ',

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, SUMMARY

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. Scope: This routine, unannounced inspection entailed 32 inspector-hours on site-in' the areas of construction progress, and housekeeping, preservice inspection (Unit 2)andinsp.ection(Units 1~and2)andinservicetestingofpumpsandvalves ' ',

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(Unit 1). -

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, <Resdits:' Nofviolations or deviations were identifie '

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8505230063 850410 PDR ADOCK 05000413 G PDR

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-REPORT DETAILS-

-- Persons' Contacted Licensee Employees

• J.1W. Cox, Superintendent of Technical Service

• G.Jr. Smith, Superintendent of Maintenance

• C.'W._ Graves,~Jr., Superintendent of Operations-

• A. S. Bhatnagar, Test Engineer

• R.l Jones, Test Engineer

• E. M. Couch, Project Manager

_ *B.1 Bright, Engineering Manager

• T.-D. Mills,-Construction Eagineer-

'*J. C.:Allgood, Electrical Tech Support

• T. H. Propst, Mechanical. Technician

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• Z. Taylor, Test Engineer

• J. Cherry, Qu;11ty Assurance (QA) Engineer

• K. Schmidt, OA ~ngineer

• E. Miller, QA Ya;ineer

• J. W. Willis, QA Engineer

• D.'Hensley, Licensing Specialist

• D. James, QA Technician

• G.-Keener, QA Surveillance Engineer Other " licensee employees contacted included construction craftsmen, engineers,-technicians, and office' personne NRC Resident-Inspectors

'*P. K. Van Doorn

• P.. Skinner

• Attended' exit interview

Exit-Interview (30703B)

The inspection scope and findings were summarized on March 29, 1985, with

.those persons indicated in paragraph 1. above. The inspector described the

areas . inspected = and discussed 'in detail the inspection findings listed-below. No dissenting comments were received from the license (0 pen) Inspector Followup Item 413/85-11-01 and 414/85-09-01: "QA Program Responsibility" - paragraph 6a(1)(a).

, (0 pen) LInspectorLFollowup. Item 413/85-11-02 and 414/85-09-02: PSI /ISI Audits" - paragraph 6a(1)(b).

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(0 pen) Inspector Foll'owup Item 413/85-11-03 and 414/85-09-03: '" Unavailable-

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> Procedures"~-paragraph-6b(1)(a).

.(0 pen)= Inspector Followup Item 413/85-11-04 and 414/85-09-04: " Level III Approval" - paragraph 6b(1)(b).

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'(0 pen)InspectorFollowupItem 413/85-11-05'and 414/85-09-05: " PSI /ISI Code

.of Record"~--~ paragraph 6b(2)(a).

(0 pen) Iaspector Followup Item'413/85-11-06 and 414/85-09-06: " Regulatory

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. Guide 1.150 Revision" - paragraph 6b(2)(b).

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(0 pen) ~ Inspector. Followup LItem 413/85-11-07: ' "IST Code of Record" -

paragraph -7a(1) .

?(0 pen) Inspector' Followup Item 413/85-11-08: "IST. Plan Change Control" - '

paragraph 7a(2).

-(0 pen) Inspector Followup Item 413/85-11-09: "IST Scheduling Procedure" -

' paragraph 7 (0 pen) Inspector Followup ' Item 413/85-11-10:- " Summary Status List" -

paragraph 7 The ' licensee did not identify as proprietary any of the materials provided to or reviewed by the inspector during this inspectio >

3. ' Licensee Action on Previous Enforcement Matters (92702B)

-This subject was not addressed in the inspectio ' Unresolved' Items-(92701B)..

Unresolved items were not-identified during this inspectio . Independent Inspection Effort (Units 1 and 2)(92706B)

Construction Progress and Housekeeping The inspector conducted a general inspection of Unit 2 containment, Units 1 and 2 auxiliary buildings, Unit 2 laydown areas and Unit 1 protected area to observe construction progress and activities such as welding, material-handling and control, housekeeping and storag .Within the areas examined no violations or deviations were-identified.

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4 s .  : 'l-3 :Preservice. InspectionI(PSI)(Unit 2)'and Inservice Inspection (ISI)'(Units 1~

-and 2):

The inspector examined documents', activities, and records as indicated below to determine whether PSI and ISI were being conducted in accordance with applicable , procedures, regulatory requirements, and licensee commitment The. applicable code for the ISI of Unit 1 is American Society of Mechanical Engineers (ASME) Boiler and- Pressure -Vessel (B&PV) Code, Section XI,1980 edition with addenda through winter 1981. The applicable code for the PSI

.of: Unit:2 is ASME B&PV Code Section XI, .1974 edition with addenda through -

the Summer 197 Review of Program (73051B)

(1) .The inspector reviewed licensee documents to ascertain whether the PSI and ISI programs had been approved by the licensee, and whether adequate QA. plans and procedures had been established -

-(written, reviewed, approved, and ' issued) to assure that organizational structure and QA personnel, audits, general QA requirements, work and quality inspection procedures, control of processes. corrective ~ action, document control, examination control and control of examination equipment, quality records, and qualification of personnel were controlled and accomplished. The following. documents were examined:

. Document Identification Title DPC-APM,-Rev. 21 " Administrative Policy Manual for Nuclear Stations" DPC-QA-131, Rev. " Quality Assurance Training" DPC-QA-230, Rev.10 " Departmental Audit Scheduling and Follow p'

DPC-QA-210 Rev. 17 " Departmental Audit Procedure" DPC-QA-130,Rev.-11 " Qualification and Training of Auditors" DPC-QA-513. Rev. 3 " Control of_Preservice and Inservice Inspection Plans" DPC-QA-100,_Rev. 8' " Preparation and Issue of Quality Assurance Procedures" DPC-QAM, Rev. 34_ " Quality Assurance -Department Quality Assurance Manual" DPC-QCK-1, Rev. 18 " Control of Nonconforming Items"

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T DPC-QAP-Q-1, Rev. 22 " Control _of Nonconforming Items"- -

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." Quality _ Assurance Department

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_DPC-QA-QCPM,Rev.-80_

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Operations-Division Quality. Control r Manual"

~DPC-QA-113. Rev. 3 " Procedure for Microfilming Records"

'DPC-QA-301, Rev. 8- " Management of Project QA Records"

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DPC-QCB-1, Rev. 20 " Control of Measuring and Test .

j Equipment and Calibration Standards"

. DPC-QAP-0-1, Rev. 26 " Control of Measuring and Test-Equipment"

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DPC-QA-116 Rev. 5 " Quality Assurance Records Collection Storage and Retention"

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DPC-QCL-5, Rev'. 5 " Control of Preservice and

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Inservice Inspection Activities"

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a~ 'DPC-QA-509, Rev. 10 " Preparation of Quality Control t

Procedures" w- -

DPC-QAP-A-1, Rev. 17 " Preparation and Issue of Quality Assurance Procedures"

~-DPC-QA-140, Rev. 8 " Quality Assurance Training"

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Inservice Inspection Plan Catawba Nuclear Station Units 1 and 2 Revision 0

. Preservice -Inspection Plan Catawba Nuclear Station Units 1 and 2, Revision 5 e

DPC - Duke Power Company B&W - Babcock and Wilcox (a) With regard to the examination above the inspector noted that neither the -ISI nor PSI' plans delineate the (QA) program coverage for the various inspections covered by DPC B&W and CONAM. The licensee indicated that they would amend both the T5Tand PSI plans to clarify this issue. This matter will be-identified as'. inspector followup item 413/85-11-01 and-414/85-09-01: "QA Program Responsibility."

(b) With regard to-the examination above the inspector was unable to find any documented objective quality evidence that the PSI /ISI programs would be covered by- the DPC audit progra y

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This matter will be the subject of additional NRC review and will . be identified as inspector followup item 413/85-11-02 and 414/85-09-02: " PSI /ISI Audits."'

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(2) To ascertain'whether the program specifies personnel qualification requirements consistent with Regulatory Guide 1.58 "Qualifica-tion of Nuclear . Power' Plant Inspection, Examination and Testing

' Personnel, " American National Standards Institute (ANSI) Standard ANSI ~ N45.2.6.and American Society for Nondestructive Testings -

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(ASNT) Standard SNI-TC-1A, the inspector reviewed ' procedure

. DPC-NDE-B, Revision 7, '" Training Qualification and Certification ,

of NDE Personnel." ,

. (3) The inspector reviewed the below listed documents to determine whether the PSI and ISI program and referenced documents contain

~a dequate provisions relative to the control of Nondestructive Examination :(NDE) records in the following areas: examination results; NDE equipment-listing; calibration ' data sheets; calibration blocks-listing; personnel qualifications; and drawings, sketches,.and work order The inspector reviewed the below listed. documents to verify that responsibilities have been assigned for maintenance of required NDE records and that controls have been established to accomplish the following: define record storage facility; designate a custodian; describe the filing system; establish a Lmethod for verification that' records and materials reviewed for storage are in agreement with transmittal documentation; provision governing access to files; and establishment of filing supplemental  ;

informatio Documentation Identification Title

.DPC-QA-102, Rev. 4 " Storage of Special Processed Records" DPC-QA-101, Rev. 4 " Quality Assurance Record-Storage Area-(General Office

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Corporate Vault)"

DPC-QA-116, Rev. 5 ." Quality Assurance Records

Collection, Storage and Retention" DPC-QA-111, Rev. 4 " Transfer of QA Records" DPC-QA-113, Rev. 3 " Procedure for Microfilming Records" DPC-QA-301, Rev. 8 " Management of Project QA Records" m-n-,

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b.: ReviewofProcedures(730528)

(1) = To ascertain whether the PSI.and ISI procedures had been approved by Authorized licensee personnel and level III examiners the-inspector. reviewed the-following procedures:

Procedure N Title B&W - 151-50, R8 " Technical Procedure Describing Surface-Requirements of Welds, Adjacent Base Metal, and Components for NDE" B&W:- ISI-55, R0 " Technical Procedure for Sulfur Content Analysis" B&W - ISI-56,.R0 ." Technical. Procedure for Halogen Content Analysis" B&W - ISI-83,.R1 " Measurement of Ultrasonic Instrument Performance Characteristics" B&W.- ISI-104, R18 " Ultrasonic Examination of Ligaments

.Between Threaded Holes and of Studs and Bolts One Inch and Larger in Diameter" B&W - ISI-105, R10 " Ultrasonic Examination of Reactor Vessel Closure Nuts" B&W - ISI-114, R4' " Ultrasonic Examination of Calibration Blocks Prior to Drilling of-Calibration Holes" B&W~- ISI-117, R5 " Ultrasonic Examination of Reactor Coolant Pump Motor Flywheel"-

B&W - 1S1-119, R3 " Ultrasonic Examination of Stainless Steel and Nickel Base Alloy Weld Seams" B&W - 151-120, R15 " Ultrasonic Examination of Piping and

. Vessel Welds Joining Similar. and Dissimilar Materials" B&W - ISI-125. R " Ultrasonic Examination for Intergranular Stress. Corrosion Cracking in Stainless Steel or Nickel Base Alloy Piping" B&W - ISI-130, R16 " Ultrasonic Examination of Vessel Welds and Nozzle Inside Radius Sections"

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B&W :ISI'-131, R9

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" Remote Ultrasonic Examination Using the-ARIS Device"

B&W ISI-240, R12 " Penetrant Examination of Weld and Base Materials, Including Studs and Nuts"

.B&W -~ISI-270, R10- " Wet or Dry Methods of Magnetic Particle Examination-of Welds, Studs, Bolts, and:

Pump Motor Flywheels"

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.B&W - ISI-350, R12 " Visual Examination of Welds and Surface Conditions" B&W - ISI-353,'R3 " Visual Examination of Pipe Hangers,.

Supports, and Restraints"

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B&W - 151-362, R10 " Identification and Layout of Welds and-System Components" B&W - ISI-423, R1 "Multifrequency Eddy Current Examination of .750"'0D x .044" Wall RSG Tubing in Westinghouse Steam Generators" B&W - ISI-424, R7 "Multifrequency Eddy Current Examination of .750" 00 x .044" Wall RSG Tubing for Detection of Tube Wear at Support Plates" B&W - ISI-425 " Eddy Current Evaluation of Tubing by the Absolute Multicoil (8 x 1) Technique for Detection of Tube Wear at-Support'

Plates" B&W - ISI-460, R5 l

" Technical Procedure for the Eva'uation of Eddy Current Data of Nuclear Grade Steam Generator Tubing" B&W - ISI-462 " Technical, Procedure for the Evaluation of Eddy Current Data for Debris and Sludge in Steam Generators"'

_, B&W - ISI-463 " Technical Procedure for the Evaluation of Eddy Current Data Generated for.the Multielement Probe" B&W - 151-464. R0- " Technical Procedure for the Evaluation of Eddy Current Data of Nuclear Grade Steam Generator Tubing for Wear Fretting"

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B&W - ISI-467 " Technical Procedure for the Evaluation of Eddy Current Data of Nuclear Grade Steam Generator Tubing for Intergranular-Attack" DPC - NDE-12,-R3 " General Radiography Procedure for Preservice and Inservice Inspection (1980,' "

DPC - NDE-25, R4 " Magnetic Inspection Technique for Preservice and Inservice Inspection (1980) Yoke Method" DPC --NDE-26, R6~ " Wet Nonfluorescent and Fluorescent Magnetic Particle Examination Techniques for Examination of Pressure Retaining Bolting"

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DPC - NDE-35. R3 " Liquid Penetrant Examination Technique (Color Contrast, Solvent Removable Method) for Preservice and Inservice Inspection (1980)

DPC - NDE-37, R0 " Liquid Penetrant Examination Technique (Color Contrast, High Temperature)"

DPC - NDE-44, R5 " Ultrasonic Examination of Bolts and Studs for Preservice and Inservice Inspection" DPC - QCL-13, R1 "ISI Visual Examination, VT-1" DPC - QCL-14, R3 "ISI Visual Examination, VT-3 and VT-4" DPC - QCL-15, R2 "ISI Visual Examination, VT-2" DPC - APP-1 " Flaw Indication Characterization" DPC - CP-453. R9 " Liquid Penetrant Examination for Case Line Inspection" DPC - NDE-11, R4 " General Radiography Procedure for Preservice and Inservice Inspection" DPC - NDE-24, R6 " Magnetic Particle Inspection Method -

Yoke Method for Preservice and Inservice Inspection" l

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DPC - NDE-33, R4 " Liquid Penetrant Examination Technique:

(ColorContrast,SolventRemovable ~

Method) for Preservice and Inservice Inspection" DPC - NDE-46, R4 " Ultrasonic Examination of Reactor Vessel Closure Nuts for Preservice and Inservice-Inspection" DPC _QA M-4, R19 " Visual Inspection and NDE of Welds (ASMEIII)

DPC - QA M-10, R21 " Process Control and Inspection of the Application of Torque or Tension to

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Bolts and Studs" DPC --QA M-12, R3_ " Valve Disassembly and Assembly Inspection" CONAM -42-EC-085, RO - "Multifrequency Eddy Current Procedure Westinghouse Series D4 and D5 Steam Generator Tubing MIZ-18 Digital Eddy Current System" (a) With regard to the examination above the inspector noted that-.

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the following procedures were unavailable for review:

B&W - ISI - 425 462 463 *

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467 DPC-APP-1 This will be identified as inspector followup items 413/85-11-03 and 414/85-09-03: " Unavailable Procedures".

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(b) With regard to the examination above the inspector was not able to verify that Procedure Nos. B&W - ISI-83,104,119, 130 and 240 were reviewed by a Level III examiner.-

This matter will be identified as inspector followup item 413/85-11-04 and 414/85-09-04: " Level III Approval."

(2)' To ascertain whether the licensee's commitments pertaining to PSI and ISI as described in the Safety Evaluation Report and the Technical . Specifications are reflected in NDE procedures, the inspector reviewed the procedures listed in paragraph 6b(1) abov I

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'(a) With regard to the examination above the. inspector noted that the ~ following PSI program referenced procedures do ' not

' reference the PSI Code Section XI edition and addenda of-record 74S75:

DPC-NDE 26 DPC-QA-M4 DPC-QA-M10 DPC-QA-M12 All the DPC Procedures and the- B&W Procedures referenced in the ISI proCram do not reference the ISI Code Section XI

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edition and addenda of record 80W8 This matter will be identified as inspector followup items 413/85-11-05 and 414/85-09-05: " PSI /ISI Code of Record."

(b) With regard to the examination above the inspector noted'that the ' Unit 2 PSI Plan referenced Regulatory Guide 1.150, Revision 1, while the Units 1 and 2 ISI Plan referenced Regulatory Guide 1.150 Revision The licensee indicated-that the ISI Plan will be amended to reflect Revision 1 vice Revision This matter will be identified as Inspector followup items 413/85-11-06 and 414/85-09-06: " Regulatory Guide 1.150 Revision."

Within the areas examined, no violations c- deviations were identifie .- Inservice' Testing (IST) of Pumps and Valves (Unit 1)

The . inspector reviewed procedures and other appropriate requirement-documents, conducted interviews with responsible personnel, and reviewed records to determine whether IST was- being performed consistent with regulatory requirements and licensee comitments. The applicable code for IST is ASME B&PV Code Section XI 80W8 The inspector reviewed the below listed documents to verify that the

. licensee had assigned responsibilities to persons and organizations for the following: preparation, review, and approval of IST procedures; scheduling of IST; performance of test functions; performance of maintenance; and performance of calibration DPC-CNSD-3.2.2 (TS), Rev 8 " Development and Conduct of Periodic Testing Program" Inservice Testing Program for Pumps and Valves Catawba Nuclear Station Unit 1 Revision 9

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.DPC-CNSD-4.2.1 (TS) Rev. 16 " Development, Approval and Use of Station Procedures"

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_DPC-MMP-1,2, Rev.'3' " Instrument and Electrical Section Procedure Development DPC-PP-5.2,'Rev. 6/14/82 " Valve Inservice Testing Program Statement" DPC-PP-5.4, Rev. 6/7/83 " Documentation of Periodic Test Development" DPC-MMP-1.0, Rev. 16 " Work Request _ Preparation" DPC-CNSD-2.3.1(m),~Re " Control of Test and Measuring Equipment"

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-(1) With regard to the ' examination above the inspector noted that the Pump and Valve Inservice Testing Program ~ Unit 1, Revision 9 references ASME . B&PV' Code Section XI 80W8 The inspector discussed this matter with the licensee. The licensee ~ indicated

- that the program would be _ amended to reflect.Section XI 80W81, the Code of record for. ISI as required by Title .10 Code of Federal Regulations. Part 50.55a(g), before commercial operatio . This matter will be' identified as ' inspector followup item 413/85-11-07: "IST Code of Record."

-(2)' With regard -to the examination above the inspector noted that

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Revision 9 ' to the IST' program contains over 100 pages, a significant number of which contain changes. The document does not have a~" list of effective pages;" therefore, without a direct comparison with the master copy of the document, it would. be impossible to determine whether other controlled copies are properly maintained and updated. The licensee indicated that they would review the matte This matter will be identified as inspector followup item 413/85-11-08: "IST Plan Change Control." To veri _fy - that the control of issuance and revision of test procedures are in accordance with applicable controlling procedures, the. inspector reviewed the below listed test procedures and revisions:

Procedure Changes /

No . - Revisions Title PT/1/A/4200/13C 0-13 "RNValveInserviceTest(QU)"

PT/1/A/4200/10A 0-19 " Residual Heat Removal 1A Performance Test"

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~12 To ' verify that tests are scheduled at required frequencies, the

., inspector had a discussion with scheduling personnel and reviewed DPC-CNSD-3.2.2 (TS), Revision 8. The inspector determined that, at '

present, pump and valve tests required by ASME ,B&PV Code Section XI

. subsections IWP and IWV are scheduled by an undocumented informal system using data from the CPT computer. program. .The CPT program

.provides the dates of previous' tests, and due dates for the next required test, but does not schedule the' next tes The licensee

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indicated that a scheduling program that includes subsections IWP and IWV tests' is currently. in preparation and should be. completely opera-

- tional' before the start of comercial operation. The inspector stated

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that the above matter would be identified as inspector followup _ item '

50-413/85-11-09: "IST Scheduling Procedure."- ,

1 .To verify that -sumary status lists, as required by ASME B&PV Code ,

Section XI, paragraph Nos. IWP-6210 and IWV-6210 are maintained- to ,

indicate the status of testing of pumps, and valves, and that the status 1.ists properly reflect scheduled ' tests,- the inspector had a -

discussion with -IST personnel and reviewed the CPT computer program

. discussed above. The licensee indicated that the CPT program currently contains the dates of the:last subsection IWP and IWV test performed on each pump and valve contained in the IST program._ The CPT program data base isLupdated, at a minimum, weekly as it related to the performance-of tests. The CPT program data base has a field for remarks that could contain such data as: operational status, increased-test frequency, alert range, and action required range. Presently the licensee has not programmatically addressed in writing compliance with IWP and IWV210. ,

The inspector indicated that this matter' be identified 'as inspector followup 1 tem 50-413/85-11-10: " Summary Status List."

Within the areas examined, no violations or deviations were identifie ,

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