IR 05000219/1979005
| ML19269E931 | |
| Person / Time | |
|---|---|
| Site: | Oyster Creek |
| Issue date: | 04/02/1979 |
| From: | Kehoe D, Kister H, Napuda G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19269E915 | List: |
| References | |
| 50-219-79-05, 50-219-79-5, NUDOCS 7906290833 | |
| Download: ML19269E931 (16) | |
Text
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Region I Report No.
50-219/79-05 Docket No.
50-219 License No.
DPR-16 Priority Category C
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Licensee:
Jersey Central Power and Light Company Madison Avenue at Punch Bowl Road Morristown, New Jersey 07960 Facility Name: Oyster Creek Nuclear Generating Station Inspection at:
Forked River, New Jersey and Morristown, New Jersey Inspection conducted: February 27 - March 2 & March 5-6, 1979
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Inspectors:
[J<
- D.tv. Kehoe, Reactor Inspector
/ date signed Y
6.giapuca, Keactor inspector dite signed
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date signed 2-f Approved by:
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'H. B. KisterT Chief, Nuclear Support
' date signed Section No. 2, RO&NS Branch Inspection Summary:
Inspection on February 27 - March 2 & March 5-6,1979 (Recort No. 50-219/79-05)
Areas Inspected:
Routine, unannounced inspection of the Quality Assurance Program in the areas of Procurement Control and Document Control, and followup on previously identified inspection findings.
The inspection involved 63 inspector-hours at the site and 29 inspector-hours at the corporate offices by two NRC inspectors.
Results:
Of the two areas inspected, one apparent item of noncompliance was identified in one area (Deficiency - storeroom did not meet the requirements of N45.2.2 and the station procedures, Detail 6).
2142 184 Region I Form 12 (Rev. April 77)
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DETAILS 1.
Persons Contacted R. Ashby, Supervisor Engineer of Projects B. Bader, QA Engineer, A-RSM J. Behm, QA Engineer, PQA-RSM E. Carlson, QA Engineer, P-RSM
- J. Carroll, Jr., Station Superintendent T. Crummins, Manager Generation Engineering
- R. Dube, Supervisor Site Quality Assurance
- S. Fuller, Jr., Asst. Supervisor Site Quality Assurance
- D. Gaines, Manager, Quality Assurance
- E. Growney, Operaticns Engineer
- W. Shirley, Supervisor Generation Storage
- W. Stewart, Sr. Administrator - Gen. Tech. Trng.
- J. Sullivan, Jr., Chief Engineer The inspector also held discussions with and interviewed other members of the technical and administrative staff.
- denotes those present at the exit interview.
2.
Followup on Previously Identified Inspection Findings (0 pen) Unresolved item (219/78-04-01): Review and evaluate the response to Audit 77-07 which is due on March 31, 1978.
The inspector deter-mined that a materials management department has been established and a materials management manual has been recently issued which will resolve this item. At the time of the inspection this manual and Procedure 2001, Administration of Procurement, Revision 3 were being reviewed by the Quality Assurance Department for consistency within interface areas and several changes had been identified.
The inspector also reviewed a sampling of procurement documents (see paragraph 5)
and detennined that the required reviews had been performed and that all necessary specifications were included.
This item will remain open pending review by NRC:RI of the implementation of the Materials Management Manual.
(Closed) Unresolved item (219/78-04-02): Review corrective action taken with respect to NCR-30 and NCR-31.
The inspector determined that the two large shipping crates associated with NCR-30 and NCR-31 2142 185
had been opened and the contents identified.
The inspector further noted that the contents were detemined to be obsolete by the licensee and were subsequently scrapped.
This item is resolved.
~(Closed) Deficiency (219/78-04-03): Failure to document results of inspections required by ANSI N45.2.2, section 6.4.1.
The inspector reviewed Procedure 121, Storeroom Instructions, Revision 1 which required the subject inspections be performed and documented utilizing a prescribed form.
The inspector further observed that these documentation forms are being used and maintained.
This item is closed.
(Closed) Unresolved item (219/78-04-04): Review corrective action associated with licensee's audit finding 77-31-08.
The inspector detemined that the computer program for drawings is functional. Also, a drawing index has been issued and will be updated as needed or yearly whichever is earlier.
In addition to the index a system of drawing change requests maintains the status of drawings between index re-visions.
This item is resolved.
(0 pen) Infraction item (219/78-04-05): Records stored in areas not meeting the storage requirements of ANG ':45.2.9 for single copy records storage.
The inspector determt.:d that the records stored in the " Room over the control room" had been removed from that area, and unnecessary records have been purged.
The remaining records were indexed and are being maintained at the site document control center.
The inspector also determined that JCP&L had contractually acquired a vault from First National Bank of Tom's River (Bricktown Branch)
that will be used for single records storage. Also, the site quality assurance manager is developing a set of administrative controls for the vault.
The licensee stated that all single records will be stored in the bank vault and administrative controls established by April 1, 1979.
This item will remain open pending review by NRC:RI of the subject records storage program.
(Closed) Unresolved item (219/78-04-06): Review document control corrective actions associated with Audit Report Records and Project Records as identified in Audit Report Finding 77-31-09.
The corrective action associated with Audit Report Finding 77-31-09 has been completed and the auditor found the corrective action to be acceptable.
The inspector noted that the licensee designates audit reports and associated documentation as records after the specific audit report is closed (e.g., disposition to all findings and observations are complete and accepted).
The audit report is then transmitted for processing into the Records System.
The inspector had no further questions.
This item is closed.
2142 186
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(Close.d) Unresolved item (219/78-04-07): No procedural requirement for time limitations for followup action on overdue audit finding responses.
The inspector reviewed Procedure 4008, Requirements for OPQA Audit Program, Revision 5, Paragraph 5.5.2.7, which states that if a response to an audit finding is not received within 30 days then the designated responsible individual shall initiate a NC/ CAR within 30 days.
This item is closed.
(Closed) Infraction (219/78-24-04): Outdated and uncontrolled prints in the control room.
The inspector determined that all hard copy prints had been removed from the control room and replaced with a controlled aperature card deck.
The aperature cards had been indexed and a viewing screen was available for use.
This item is closed.
(Closed) Unresolved item (219/78-24-05): Delays in revising prints.
The inspector determined that the delays in revising prints was due primarily to the poor quality originals (which in many cases required the complete redraf ting of the drawing) and to the large influx of drawings from the Architect-Engineer.
The latter were being acquired by the licensee in order to augment the current collection of Oyster Creek drawings. The inspector also determined that the as-built condition of. any drawing could be determined by using the latest revision of the master index and all outstanding drawing change requests.
This item is resolved.
(0 pen) Unresolved item (219/79-02-04): Review QA training procedure and training records.
The inspector reviewed various procedures and training records and identified that the training of new site QA personnel was not being documented using the prescribed fonns.
It was determined that the training program was being revised and that the revised procedure was in the review cycle.
It was further deter-mined that new personnel were being evaluated using the revised pro-cedure on a trial basis.
It was also noted that the major program change that is being considered is the replacement of the Training Coordinator by one staff and one site coordinator with responsibilities limited to maintaining training records.
In the future, all training and certification will be performed by the appropriate supervisor.
The program revision is expected to be completed by August 1,1979.
This item will remain open pending review of the revised program by NRC:RI during a subsequent inspection.
3.
Quality Assurance Program Review The inspectors noted that JCP&L had submitted a major revision to their Quality Assurance Program to NRC:NRR.
The licensee stated that through 2142 187
oral communication with NRR it has been established that a number of questions were forthcoming from that office.
The licensee is in the process of revising corporate type implementing procedures to be consistent with the currently submitted program particularly in the area of the recently established Materials Management Department.
The inspectors reviewed selected areas of the submitted program and determined that it apparently was equal to or more conservative than the currently approved program. The examination of the implemented revised quality assurance program will be conducted after final NRR approval of the submitted program.
4.
Document Control a.
References 103, Station Document Control, Revision 1
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107, Procedure Control, Revision 10
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121, Storeroom Instructions, Revision 1
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2004, Generation Department Document Control, Revision 0
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2005, Generation Department Document Retention, Revision 0
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2009, Control and Distribution of As Built Drawings, Revision 0
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2014, Generation Department Document Center Organization
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and Responsibilities, Revision 0 3011, Site Quality Assurance Document Control, Revision 0
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5003, Nuclear Generating Station Staff Document Control,
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Revision 0 7003, Generation Maintenance Document Control, Revision 0.
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b.
Program Review The above procedures were reviewed on a sampling basis to verify that the control of documents meet the requirements of ANSI N45.2.11 and ANSI N18.7 as modified by the submitted revised QA Program.
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The review verified that administrative controls provide for the control of drawings, including the maintenance of current as built drawings; distribution of drawings to the appropriate parties in a timely manner; a mechanism to distribute documents other than drawings; a periodic review of documents other than dradings; a method of determining the latest revision of all documents; and, assignment of responsibilities.
No items of noncompliance were identified.
However, two unre-solved items are discussed below.
(1)
The inspector observed that all Drawing Change Requests (DCR's) associated with a given drawing are discarded when a later revision number of that drawing appears on the dis-tributed general revision to the Drawing Index.
The inspector noted that there was no method established by which the holders of aperture cards / drawings could determine if an existing DCR still applied to that revised drawing. The inspector also observed that the Control Room and Document Control Center (DCC) are the only station holders of con-trolled aperture card decks and could therefore update their Drawing Indices to the latest specific drawing revisions upon receipt of the revised drawings (aperture cards) which are issued in the interim period between General Revisions to the drawing index.
The inspector noted, however, that other holders of controlled copies of the Drawing Index had no method by which they could update their copies during the subject interim period.
During an interview, the DCC Super-visor stated that no DCRs had been issued since the most recent general revision to the Drawing Index (flovember 1978).
The licensee acknowledged the above problen and stated that the necessary action would be taken to update all holders of Drawing Indices with regard to the DCRs and specific drawing revisions issued in the interim period between General Revisions to the Drawing Index.
A system will also be established which will ensure that all Drawing Indices will be maintained up-to-date.
The licensee stated that the necessary action would be completed by June 1,1979.
This item is unresolved pending review by NRC:RI during a subsequent inspection of the above licensee's actions.
(219/79-05-01)
2142 189
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(2)
Procedures 2004 and 5003 (Paragraph 5.8) appear to state that the corporate Document Control Center (DCC) will distribute instructions / procedures etc.
Various procedures reference other procedures such as 6006, 6007, 6008 and 6010.
Procedure 2004 requires that each department establish a departmental procedure that specifically addresses document control.
The inspector noted that the corporate and station DCC's distribute those documents that originate at their respective location.
The inspector also noted that many procedures re-quired that an activity be accomplished in accordance with a referenced procedure which had been rescinded or never established.
Further, the inspector noted that some depart-ments addressed document control in a number of procedures rather than in a specific procedure established for that purpose.
The licensee acknowledged the above condition and stated that the subject discrepancies had been identified, resolutions had been proposed, and efforts were underway to review and revise corporate type procedures where necessary (series 2000 through 7000).
The licensee further stated that the fore-going was documented in internal Audit 77-31 and a Management by Objectives Goals and Objectives Manual (MOG0).
The inspector reviewed the above documents and letter GM-79-15 and verified that the documents identified the same or similar discrepancies / problem areas as those of the inspector.
The inspector noted that the M0G0 discussed all internal open audit findings, review / revision of Generation / Maintenance / Construction Departments' procedures and departmental reorganizations along with required action (s), task assignments and target dates.
The inspector stated that this item is unresolved pending review by NRC:RI during a subsequent inspection of the licensee's actions with respect to the document control area.
(219/79-05-02)
c.
Implementation Review The controls of the following documents were reviewed to verify that the progranmatic controls identified in 4.b above were being implemented.
2142 190
Drawings 237E487 System Diagram for
15 15 15 15 CRD Hydraulics 237E566 Sh-1 Reactor Protection 15 17 17 17 17 System 148F740 Containment 12 12 12 12 12 System Spray 237E901 Elementary Diagram
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7
Containment Spray 706E249 CRD Hydraulic
3
3
System 3001-Main One Line
7
7
Diagram 3029 Elementary Diagram
11
11
D.C. Control 3028 D.C. One
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10 11 Line Diagram 885D781 Core Spray
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11
237E798 Reactor and
11
11
Recirculation Loop 3033 D.C. One Line Dia.
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1 Battery C 3013 Vital One Line 14 14 14 14 14 Diagram
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Other Documents Procedure 116 Random Selection from 100 Series Procedure 203.2 Random Selection from 200 Series Procedure 406.3 Random Selection from 400 Series Procedure 517 Random Selection from 500 Series Procedure 602.4001 Random Selection from 600 Series Procedure 702.0.019 Random Selection from 700 Series Procedure 901.8 Random Selection from 900 Series QA Plan Tech. Specs.
Master Drawing Index 2142 191
No items of noncompliance were identified, however, two unresolved items are discussed below.
(1) Procedure 2004 states that the indices to document series on the Controlled Document Listings will be issued monthly.
The inspector observed that the corporate DCC issues copies of their Document Indices monthly; however, the site DCC issues copies of their Document Indices only when a revision is necessary.
The licensee acknowledged the above and stated that the procedure and practices would be reviewed.
The licensee further stated that either, or both of the. practices and procedure would be revised by April 1, 1979, so that they are consistent with each other.
This item is unresolved pending review by NRC:RI during a subsequent inspection of the above licensee's action.
(219/79-05-03)
(2)
During this inspection the licensee was implementing the corrective action specified in their letter to NRC:RI dated October 6, 1978.
The inspector observed that a number of the hard copy drawings maintained in the Control Room were not of the latest revision. With respect to Drawings 3033, 3013, and 3028 the inspector determined that although the lastest hard copy revision was numbered the same as the latest revision listed in the Drawing Index, the hard copy was not an approved version and it differed in content from the approved revision (original and aperture card).
Prior to the conclusion of this inspection the corrective action specified in the licensee's letter dated October 6, 1978 was completed.
The inspector observed that the controlled Drawings (aperature cards) now being maintained in the Control Room as a result of the above stated corrective action were of the latest approved revision.
As a result of this corrective action all hard copy drawings maintained for general Control Room use were removed from that location.
Further, the licensee stated that all drawings being maintained by individual oper-ating personnel would be reviewed and all drawirjs whose revision (s) were unapproved would be discarded ~y April 1, o
1979.
This item is unresolved pending review by NRC:RI during a sub-sequent inspection of the above licensee's action. (219/79-05-04)
2142 192
5.
Procurement Program a.
References
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117, Material Identification and Control, Revision 0 119, Housekeeping, Revision 2
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121, Storeroom Instructions, Revision 1 2001, Administration of Procurement, Revision 3
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2011, Content of Procurement Documents, Revision 0
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2023, Noting Procurement Documents in Accordance with Rules
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in Accordance with 10 CFR 21, Revision 1 3003, Site Quality Assurance Receipt Inspection of M1terials,
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Parts or Components, Revision 2 3005, Site Material Conformance Identification, Revision 3
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4005, OPQA Control of Nonconformances and Corrective
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Action, Revision 1 4007, OPQA Procurement Verification, Revision 5
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4016, Procurement Document Review, Revision 1
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4017, Administrative Control of Procurement Verification,
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Revision 5 4018, 0QA Shipment Release, Revision 1
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4020, 0QA Evaluation of Contractors, Revision 1
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4021, Contractor Appraisal, Revision 2
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4022, Contractor Audits, Revision 1
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4023, Contractor Classification Lists, Revision 1
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4025, Procurement Control, Revision 0
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4010, Contractor Surveillance, Revision 3
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2142 193
b.
Program Review The above procedures were reviewed on a sampling basis to verify that the control of procurement meets the requirements of ANSI N45.2.2 and ANSI N45.2.13 as modified by the submitted revised QA Program.
The above reviews verified that administrative controls provide for: specific identification of the item to be procured; identifi-cation of any specific handling, shipping and/or storage require-ments; contractor / supplier surveillance; initiation, review, and approval of procurement documents; identification of quality classification of procured items; establishing and maintaining an approved contractor's list; and, assignment of responsibilities.
The inspector identified that Procedure 2001 references Procedure 4009 and 4023 for contractor selection.
The inspector noted that Procedure 4009 had been rescinded.
The licensee acknowledged the inspector's comment and stated that 4023 now contained all infor-mation required for contractor selection.
The licensee further stated that the cover page to the Rescinding Notice would be changed to read "This procedure is rescinded, refer to 4023 for contractor selection." The inspector detennined that this action was completed prior to the end of the inspection.
The inspector had no further questions.
No items of noncompliance were identified.
c.
Implementation The following purchase order packages were reviewed to verify that the programmatic controls identified in 5.b above were being implemented.
Purchase Order PDQ Number Description 18043 78-279(b)
CRD water quality modification 18027 78-392 CRD water quality modification 18030 78-394 CRD water quality modifica tion 2142 194
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16176 78-248 Recirc. Pump Trip Modification Conduit Installation 18064 78-433 Recirc. Pump Trip Modification Conduit Installation 18090 78-467 Recirc Pump Trip Modification Conduit Installation 11471 77-157 Containment Spray Heat Exchanger Installation 18413 78-364 Containment Spray Heat Exchanger Installation 19889 78-241 Fire Protection for A & B Battery Room No items of noncompliance were identified.
However, four unresolved items are discussed below.
(1) Procedure 4023 states that the Contractor Classification List will be reviewed monthly and updated as required.
Reasons for updating include changing the status of a con-tractor on the list, adding a contractor to the list, de-leting a contractor from the list, etc. The inspector deter-mined that the Contractor Classification List had not been revised since January 10, 1978.
This condition had been previously identified on a licensee nonconformance report (NC/ CAR 78-047).
The corrective action states that due to the complexity of the list and the large number of contractors required, the list was being entered into a computer program.
The corrective action further stated that as soon as the program was complete a new revision would be issued and sub-
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sequently reissued on a periodic basis.
During the interim
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period the Contractor Classification List would be updateo by memos.
The licensee acknowledged the above and stated that the Con-tractor Classification List was being maintained as one of the QA Department's objectives on Senior Management's " Manage-ment by Objectives List." The licensee further stated that the committed actions of the nonconformance report would be complete by June 30, 1979.
2142 195
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This item is unresolved pending review by NRC:RI of the above actions.
(219/79-05-05)
(2) The inspector determined that there were no written controls identifying the use of the memos which are presently used for updating the Contractor Classification List.
The licensee acknowledged the inspector's comments and stated that Procedure 4023 would be revised to include written controls for the use of the subject memos.
The licensee also stated that the written controls would be implemented by March 15, 1979.
The licensee further stated that the memos would become a pennanent part of the system and would be used to update the Contractor Classification List between the period revisiens of the List.
This item is unresolved pending review by NRC:RI of the above action.
(219/79-05-06)
(3)
The inspector identified two contractors who had performed unsatisfactorily as suppliers during October 1978.
The inspector further determined that even though the licensee had identified the problem, both the contractors were still listed as fully qualified suppliers as of March 2,1979.
The licensee acknowledged the above condition and stated that the written controls in c.(2) above would include provisions to preclude this from rectrrliig.
The licensee also stated that if a memo is issued which affects a contractor on the list then the written controls will require a pen and ink change to the list to annotate the change promulgated by the memo. The licensee further stated that this action would be complete by March 15, 1979.
This item is unresolved pending review by NRC:RI of the above action.
(219/79-05-07)
(4) The inspector identified that the suppliers used for PDQ Packages78-279(b),78-248, and 78-241 were not on the Contractor Classification List. The inspector determined that PDQ Package 78-241 did not fall under the review of the QASL at the time the purchase was accomplished and therefore the supplier was not required to be on the list.
The inspector further determined that the technical and quality evaluations necessary to place a contractor on the Contractor Classification List had been performed and two contractors had been found acceptable.
2142 196
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The licensee acknowledged the inspector's comments and stated that additional procedure controls would be imple-mented by December 1979 to further require that a contractor be on the Contractor Classification List prior to being used.
This it.;m is unresolved pending review by flRC:R: of the above action.
(219/79-05-08)
6.
Storercom Tour The inspector toured the station storeroom and reviewed the following areas: general storage conditions; conforming and nonconforming material identification and segregation; and, general housekeeping practices.
The inspe-tor identified several nonconformances with respect to Station Aaministrative Procedure 110, Handling and Storage; 117, Identification and Control; and, 121, Storeroom Instructions.
The above procedures were developed in accordance with the JCP&L Operating Quality Assurance Manual which requires use of the guidance provided in AflSI f145.2.2, Packaging, Shipping, Receiving, Storage and Handling of Items for fluclear Power Plants.
The nonconformances are listed below:
A surge guard pulsation reducer and a Powell ball valve with
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. pipe nipple were found stored on a OA shelf with no identifi-cation as required by Procedure 117, paragraph 4.1.
QA weld rod was found stored with non-QA weld rod and weld rod
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with no identification.
This is contrary to Procedure 117, paragraphs 4 and 5.
Hazardous material was found stored in close proximity to QA
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items in a room with no ventilation.
Procedure 121, paragraph 5.4 and AftSI f145.2.2 require that hazardous material shall be stored in well ventilated areas and not in close proximity of nuclear plant items.
Boxes of material were found not stored on pallets or shoring
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as required by Procedure 110, paragraph 5.2.
Also, boxes were stacked to a height that caused deformation of lower boxes and the potential for damage to box internals whic.h is not in con-formance with Procedure 121, paragraph 5.3.
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An open soft drink can was found in the QA storage area.
The
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use or storage of food or drinks is prohibited in any storage area by ANSI N45.2.2, section 6.2.
No means existed by which classification of individual items,
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with regard to storage level requirements, could be determined.
Thus, it could not be determined that material was being stored in accordance with the levels required by Procedure 110, para-graph 5.2.2 or Procedure 121, paragraph 5.
The storap level of tb QA storeroom was not identitied as
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required by Procedure 110, paragraph 5.2.2 and 121, paragraph 5.
The outside QA storage area was not identified as required by
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Procedure 121, paragraph 5.1.4.1.
Valves and pipe, which were annotated " Released for Use" were
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found with open ends, i.e., not plugged, sealed or capped as required by Procedure 110, paragraph 5.2.4.
The inspector verified that the first five examples were corrected prior to the conclusion of the inspection.
During a subsequent telephone conversation on March 13, 1979 between Mr. H. B. Kister, NRC:RI, and Messrs. DuFresne, Gaines and Lindbergh of JCP&L, the licensee stated that additional actions had been, and are being taken to promptly correct the deficient warehouse conditions that were identified by the inspector.
It was expected that the interim actions would essentially be complete within three weeks.
The licensee further stated that the contract for the new automated warehouse facilities had been let on January 1,1979 and was expected to be completed by September 1, 1979. When completed, all warehousing would be promptly transferred to the new facility.
7.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of non-compliance or deviations.
Unresolved items identified during this inspection are discussed in paragraphs 4.b. 4.c and 5.c.
2142 198
8.
Exit Interview The inspectors met with licensee representatives (denoted in para-graph 1) at the conclusion of the inspection on March 6,1979.
The scope and findings of the inspection as stated in this report were presented during this meeting, and subsequently discussed during a telephone conversation between Mr. H. B. Kister. IE:RI and Messrs.
DuFresne, Gaines and Lindbergh of JCP&L. The Plant Superintendent and/or the Manager - Quality Assur nce verified the target dates for the unresolved items discussed herc:n.
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