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APPENDIX B

U. S. NUCLEAR REGULATORY COMMISION

REGION IV

Report No. 50-298/82-04

Docket No. 50-298 License No. DPR-46

Licensee: Nebraska Public Power DistrictP. O. Box 499Columbus, Nebraska 68601

facility Name: Cooper Nuclear Station

Inspection At: Cooper Nuclear Station

Inspection Conducted: February 8-12, 1982

Inspectors: // ) W MM DJ[ /t.' Boardman, Reactor Inspector DateRMctor Project Section B (Paras.1,2,3,4,7)

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D/ LM. E. Murphy,' Reactor Jhspector '

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Reactor Project Section C (Paras. 1,5,6)

Approved: /u'6[ SM'f'!82W. A. Crossman, Chief DateReactor Project Section B

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R. E. riall, Ctiief / D[teReactor Project Section C

Inspection Summary

Inspection Conducted During The Period of February 8-12, 1982(Report 50-298/82-04)Areas Inspected: Routine, unannounced inspection including procedures; procure-ment activities related to material requisitioning, receipt, storage, andidentification; controls for test and measuring requirement; and control andevaluation of surveillance testing, calibration, and inspection. The inspectioninvolved 68 inspector-hours on site by two NRC inspectors.

8204120252 820331DR ADOCK 05000298

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Results: In the four areas inspected, no violations were identified in threeareas, and one apparent violation was identified in the fourth area (violation -failure to have documented procedures paragraph 3)

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Details

1. Persons Contacted

P. Borer, Engineering SupervisorB. Brungardt, Surveillance CoordinatorC. Goebel, Administrative SupervisorH. Jantzen, I&C SupervisorL. Lawrence, Maintenance SupervisorD. Majeres, Maintenance Planner

*G. Smith, Quality Assurance SpecialistD. Norvell, Electrical Supervisor

*P. Thomason, Acting Operations Supervisor*D. Whitman, Technical Assistant to the Station Superintendent

*Present at Exit Interview.

The NRC inspectors also contacted other licensee personnel, includingclerical, administrative, and maintenance personnel.

2. Licensee Action on Previous Inspection Findings

(Closed) Open item (8106-02). The licensee had not required anengineering review of documentation of material conformance. This reviewis now included in licensee Administrative Procedure 1.11, Revision 17," Requisitioning, Receiving, Storage of Essential Parts and Components."

(Closed) Violation (8106-01). Licensee receiving reports were not beingsigned as being inspected and "CNS Stores Requisitions" were not properlycompleted as required by CNS Administrative Procedure 1.11, Revision 16.A review of 20 receiving reports and 75 "CNS Store's Requisitions"revealed no further problems in this area.

3. Material Procurement, Receipt, Storage, and Handling

The NRC inspector reviewed the licensee's program and implementing procedurasfor receipt, storage, and control of equipment and materials, includingrepair parts, for compliance with Appendix B to Part 50 of Title 10, Codeof Federal Regulations and " Cooper Nuclear Station Quality AssuranceProgram for Operation," Revision 8, dated August 20, 1979.

A review of stored material revealed the following apparent problems withsquibs (primers) used in explosive (shear) valves for the Standby LiquidControl (SLC) System and the Transversing In-Core Probe (TIP) System.

a. Licensee Administrative Procedure 1.11, Section 1.11.5.4.3 requiresstorage of hazardous essential material and parts in accordance withAdministrative Procedure 1.6.8. Squibs purchased on order 133738

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were marked " Class C Explosives" with a Department of Transportation(DOT) hazardous material label, but were not covered by the licenseeprocedure 1.6, " Personnel and Equipment Safety," section 1.6.8," Hazardous Material Control." Squibs included as stored materialon licensee purchase orders 45338, 129388, and 174065 were notidentified as hazardous material. This will remain an open itemuntil the licensee has verified that his procedures and control ofthese squibs as hazardous material are adequate (8204-02).

b. The three remaining squibs purchased on licensee order 174065 aremarked " MFD 2/81," indicating that they were manufactured in February1981, and the licensee's shelf life control is based on that date.The squibs are also marked with the lot number " HEC 80J005-001."The official records for Purchase Order 174065 contain lotacceptance test reports for lot HEC 80J005-001 stating that this lotwas tested September 16, 1980, 5 months before the indicated manufac-turing date. The remaining squib on licensee order 129388 is markedwith a manufacture date of October 1977. There is no supplier docu-mentation of this manufacturing date or of the test date, only acertificate of compliance. (The licensee also tested a squib on thisorder.) This will remain an open item until the licensee hasobtained verification of the manufacturing dates of the subject squibs(8204-03).

A squib on order 174065 is installed in Train A and a squib on order129388 is installed in Train B of the SLC system.

Weaknesses in the licensees identification and handling of essentialcomponents, materials, and parts requiring shelf life control wasidentified in NRC Inspection Report 50-298/81-06. The licensee hasmade some progress in establishing a computer program for shelf lifecontrol, but has not established a formal, documented program ofshelf life control.

10 CFR Part 50, Appendix B, Criterion V, requires that activitiesaffecting quality shall be prescribed by documented instructions orprocedures.

The " Cooper Nuclear Station Quality Assurance Program forOperation," Revision 8, dated August 20, 1979, sections 2.4 and 2.5,state that quality assurance activities and other activities whichhave nuclear safety significance will be prescribed by documentedinstructions or procedures and specifically that licensee proceduresshall include provisions for assuring that necessary qualityrequirements are incorporated directly into purchase orders andcontracts for essential spare parts, material, and equipment shallalso include provisions for assuring that necessary records aresupplied to the purchaser by the supplier.

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Licensee Administrative Procedure 1.11, Revision 17," Requisitioning, Receiving, Storage of Essential Parts andComponents," dated December 8, 1981, does not require identificationof shelf life requirements, documentation of shelf life fromsuppliers, or control of shelf life after receipt of materialrequiring this control.

Failure to prescribe activities affecting quality in documentedinstructions or procedures is an apparent violation of 10 CFR Part50, Appendix B, Criterion V (8204-01).

4. Procedures

The inspector reviewed the following licensee approved procedures forcompliance with regulatory requirements, including TechnicalSpecification requirements, and with " Cooper Nuclear Station Quality

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Assurance Program for Operation," Revision 8, dated August 20, 1979, andfor apparent technical adequacy.

Procedure ApprovalNumber Title Revision Date

Administrative

1. 3 Procedures 6 2/26/811.10 Nonconformance and Corrective

Action 12 3/16/811.11 Requisitioning, Receiving, Storage

of Essential Parts and Components 17 12/8/81

General Operating Procedures

2.1.2 Hot Start-up Procedure 14 10/9/812.1.15 Reactor Recirc Pump Operation 9 3/3/80

System Operating Procedures

2.2.1 Automatic Depressurization System 14 11/19/812.2.67 Reactor Core Isolation Cooling 18 11/18/812.2.68 Reactor Recirculation System 19 1/22/822.2.74 Standby Liquid Control System 12 5/4/81

Alarm Procedures

2.3.2.21 Panel 9-3, Annunciator 9-3-1 6 6/9/802.3.2.24 Panel 9-4, Annunciator 9-4-1 8 10/15/802.3.2.25 Panel 9-4, Annunciator 9-4-2 8 4/9/812.3.2.26 Panel 9-4, Annunicator 9-4-3 6 11/6/802.3.2.28 Panel 9-5, Annunicator 9-5-2 7 10/3/81

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Procedure ApprovalNumber Title Revision Date

Abnormal Procedures

2.4.2.2.3 Recirc Pump A or 8 Seal Failure 2 10/5/812.4.2.2.4 Reactor Vessel Cold Water Stratifi-

cation 3 2/22/782.4.2.2.5 JET Pump Flow Failure 3 8/28/812.4.2.3.1 Relief Valves Stuck Open 10 8/28/812.4.2.3.1 Relief Valve Inoptrable 4 6/2/80

Surveillance Procedure

6.3.8.4 SLC Manual Initiation Test Tank to RV 8 10/21/81

Maintenance Procedure

7.2.22 Main Steam SRVs Periodic Testing,Inspection, Removal & Installation 6 10/5/81

7.2.25 Standby Liquid control SystemExplosive (Squib) Valve InsertReplacement 4 3/19/80

7.2.49 Inspection and Repair of ASCOSolenoid Valves 0 1/12/81

7.2.50 Limitorque SMB Valve OperatorsRemoval, Overhaul, and Replacement 1 12/17/81

Quality Assurance Instructions (QAI)

QAI-9 Guidelines for Establishing QualityClassifications of Components andMaterials 7 6/1/81

Quality Assurance Plan (QAP)

QAP-1400 Procurement and Control of EssentialSpare Parts, Materials andEquipment 10 10/3/80

No deviations or violations were identified; however, System OperatingProcedure 2.2.67, section VII.H, step 27, page 18, states " Ensure systemis in a standby configuration as per section VIII.A, steps 1. through 10."There is no section VIII; this apparently should read "section VII."

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The NRC inspector noted that Administrative Procedure 1.11,Section 1.11.3.1.1, requires the use of the guidelines established byCNS Instruction letter #75-1 for determination of classification ofessential parts, equipment, and materials in lieu of Table 1 of " CooperNuclear Station Quality Assurance Program for Operations" in addition,QAI-9, Revision 7, dated May 1,1981, " Guidelines for EstablishingQuality Classifications of Conponents and Materials" provides necessarydetails not covered by Table 1, but is not invoked by AdmininistrativeProcedure 1.11. This will remain an open item until AdministrativeProcedure 1.11 has been revised to incorporate the latest licensee require-ments for identification of essential items (8204-04).

It is further noted by the NRC inspector that Administrative Procedure 1.3," Procedures," does not require a review of procedures to assure compliancewith 10 CFR Part 50.59, nor is there documentation of such a raview.Licensee personnel stated that procedure review by the Station OperationsReview Committee (50RC) per se constitutes the required 10 CFR Part 50.59review and that specific cerIIfication is not considered necessary.

5. Surveillance Testing, Calibration Control, Test and MeasurementEquipment Programs

The purpose of this inspection was to review the licensee's program forsurveillance testing and calibration control for plant process andtest and measurement equipment. This review was to verify that thelicensee's programs as developed and implemented conform to therequirements of technical specifications section 4, 10 CFR 50.55(a) and(g), Regulatory Guide 1.33 and IEEE 336.

The scope of this inspection included discussions with technicians,supervisory, and coordination personnel, review of surveillance testingand calibration schedules, logs, and status reports, and the review of thefollowing records and procedures:

Test instrument data records for Test Instruments 15-1793, 15-2514,15-2541, 15-2633, and 15-2682, and Nonconformance Report 002338.

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Procedure ApprovalNumber Title Revision Date Comments

6.2.2.16 CSCS Discharge Piping Full LowPressure Alarm Calibration andFunctional Test 7 6/6/81 Note 1

6.2.2.2.1 ADS Water Level Calibration andFunctional / Functional Test 13 6/25/81 Note 1

6.2.2.2.3 ADS Timer Calibration and ActuationFunctional Test 14 10/3/80 Note 1

6.2.2.3.6 HPCI Pump Low Suction PressureCalibration and Functional /Func-tional Test 8 8/4/80 Note 1

7.1. 2 Calibration Procedure for TestEquipment 5 7/13/81 Note 2

7.5.4.1 Manometer Inspection and MaintenanceProcedure 8 12/24/81 Note 2

7.5.4.2 Pressure Test Gauge Calibration 14 7/21/81 Note 27.5.4.3 Deadweight Pressure Tester Calibra-

tion Procedure 5 5/1/81 Note 27.5.4.4 Mean Square Voltage / Wide Range

Monitor Test Alternator CalibrationProcedure 3 4/28/81 Note 2

7.5.4.5 Emergency Core Cooling System TestSwitch Maintenance 0 7/2/80 Note 2

Notes: 1. Reviewed Surveillance Testing and Calibration Data Sheets forthese surveillance procedures.

2. Reviewed these procedures.

No items of noncompliance or deviations were identified.

6. Barge Traffic

Paragraph 5.7 of the technical specifications states:

" Barge traffic on the Missouri River past the site has been analyzed todetermine that the present size and cargo materials do not create a hazardto the safe operation of the plant. Contact will be maintained with theCorps of Engineers to determine if and when additional analyses arerequired due to changes in barge size or cargo."

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The NRC inspector discussed this requirement with a licensee representativeand determined that a memo to the Corps of Engineers from the stationsuperintendent dated April 24, 1980, was on file. There was no apparentresponse and this appears to be the only contact since the originalrequirement in 1973/74. The NRC inspector voiced concern over the apparentlack of response and follow-up. The licensee's representative said thatthis would be investigated. This will remain an open item pending licensee'sresolution (8204-05).

7. Exit Interview

An exit interview was conducted on February 12, 1982, with those NPPDpersonnel denoted in paragraph 1 of this report to summarize the scope ofthe inspection and the findings.

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