IR 05000269/1990015
| ML15224A677 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 06/05/1990 |
| From: | Blake J, Newsome R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML15224A676 | List: |
| References | |
| 50-269-90-15, 50-270-90-15, 50-287-90-15, NUDOCS 9006200248 | |
| Download: ML15224A677 (11) | |
Text
kRE UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTA STREET, ATLANTA, GEORGIA 30323 Report Nos.:
50-269/90-15, 50-270/90-15, and 50-287/90-15 Licensee:
Duke Power Company 422 South Church Street Charlotte, NC 28242 Docket Nos.:
50-269, 50-270, License Nos.:
DPR-38, DPR-47, and and 50-287 DPR-55 Facility Name: Oconee 1, 2, and 3 Inspection Conducted: May 21-25, 1990 Inspectors:
j 61/
--
_______
.
Newome bat Signed Approved by.
-
_4 Jpp v d B:ak hief Date Signed aterials nd Processes Section Engineer'ng Branch Division of Reactor Safety SUMMARY Scope:
This routine, unannounced inspection was conducted on-site in the area of maintenanc The inspection included a review of the maintenance program and program implementing documents; reviews of current and historical maintenance work requests; reviews of preventative and corrective maintenance procedures; observations of in-progress maintenance activities; reviews of maintenance personnel qualifications; and, reviews of equipment calibration documentatio Results:
In the areas inspected, violations or deviations were not identifie All areas inspected indicated adequate control of the maintenance progra Both the preventative maintenance and corrective maintenance programs are well defined and being administered effectivel Management is deeply involved in all aspects of the maintenance progra First line supervisors appear to be very knowledgeable of controlling guidelines and the capabilities of subordinate personnel under their directio Engineers and mechanics engaged in maintenance activities appeared to be well qualifie Although minor isolated discrepancies were noted during this inspection, none appeared to have any significant affect on the safe operation of the plan l6 20 0 24 goes
FDR ADOCK 000 C)26
REPORT DETAILS Persons Contacted Licensee Employees
- H. Barron, Plant Manager D. Clardy, Maintenance Planning and Scheduling
- B. Foster, Superintendent, Maintenance W. Holcombe, Supervisor, Maintenance E. Merritt, Supervisor, Maintenance
- B. Millsaps, Manager, Engineering
- S. Perry, Compliance
- M. Tuckman, Nuclear Plant Division, General Manager, Nuclear Support Other licensee employees contacted during this inspection included craftsmen, engineers, security force members, technicians, and administrative personne NRC Resident Inspectors
- M. Skinner, Senior Resident Inspector L. Wert, Resident Inspector
- Attended exit interview 2. Maintenance Program and Maintenance Program Implementation (62700) (62702)
a. The below listed documents were reviewed to determine if the licensee's maintenance program is in conformance with Technical Specifications, regulatory requirements, commitments in the license application, and industry guides or standard Station Directives Revision Date 2. Document Control 4-9-89 3. Work Request 2-6-90 3. Tools and Test Equipment Control 4-11-89 4. Training and Qualification 12-6-89 4. Qualification of Interfacing 12-6-89 Individuals 4. QA Condition Determinations 11-14-85 Maintenance Directive Revision Date 7. Preventative Maintenance Program 3-8-89
Maintenance Manual Revision Date 2. Proper Application of QAIEQ Parts and 2-4-89 Material Procedure 3. Personnel Requirements For Qualifying 9-12-88 to Maintenance Procedures (I&E)
3. Maintenance Housekeeping Program (P&S) 9-29-89 3. Maintenance Group Drawing and Document 3-18-90 Control (I&E)
3. Classroom Training and OJT Evaluation 8-15-86 Semi-Annual (I&E)
3. Equipment Qualification Program (I&E)
1-26-89 3.2.12 Technical Support Program 4-5-88 3.2.18 Cleanliness In Safety Related Areas 4-10-90 4. BE Test Equipment Control 8-11-88 5. Welding Program 5-2-87 5. Lubrication Program 2-10-89 5. PM-2 Program 10-6-87 6. Tools And Test Equipment Control 11-5-88 6. Mechanical Maintenance Procedure and 6-16-89 Policy 6.3.11 Maintenance Measuring and Test 2-8-88 Equipment Control 7. Maintenance Management Report 8-15-89 Generation System 7. Receipt and Entry of Plant Equipment 1-20-89 Information 7. Preventive Maintenance Program 3-8-89 7. Schedule For Performing Instrument 9-21-87 Procedures And Out of Tolerance Notifications to Performance 7. Work Request Initial Processing 8-17-87 7. Work Request Implementation 1-23-89 7. Work Request Completion 2-18-90 7. Work Request Flow Path 10-25-88 Nuclear Production Department Employee Training &RQualification System Revision Date 240 Mechanical Maintenance Training And 3-1-90 Qualifications Overview Standard No. ONS 403.0, ONS Mechanical Maintenance Lesson Plan Revision System 250 Instrument & Electrical Training And 2-1-90 Qualification Overview (1) The above listed documents, relative to the licensees corrective maintenance program, were reviewed to confirm that:
written procedures have been established for initiating requests for routine and emergency maintenance; criteria and
responsibilities have been established for review and approval of maintenance requests including emergency maintenance requests; criteria and responsibilities have been established that form the basis for designating the activity as safety-related or not safety-related; criteria and responsibilities have been designated for performance of inspections and maintenance activities; provisions and responsibilities have been established for the identification of appropriate inspection hold points related to maintenance activities; methods and responsibilities have been designated for performing functional testing of structures, systems, or components following maintenance work and/or prior to their being returned to service; administrative controls for maintenance activities require that applicable records will be prepared, assembled, and reviewed for transfer to records storage; responsibility has been established to assemble and review the maintenance records for transfer to record storage; a program has been established for reviewing completed corrective maintenance records to assess the adequacy of the preventive maintenance program, to identify repetitive failures of parts and components, and to identify design deficiencies; work control procedures have been established to require special authorization for activities involving welding, open flame, or other ignition sources and take cognizance of nearby flammable material, cable trays, or critical process equipment; and, revisions to Technical Specifications have been incorporated into procedures and included in the master progra (2) The above listed documents, relative to the licensee's preventative maintenance program, were reviewed to confirm that a written preventive maintenance program for safety-related structures, systems, and components has been established and includes:
responsibility for the program; master schedule for preventive maintenance; documentation and review of completion of preventive maintenance activities; responsibilities and methods for establishing preventive maintenance frequencies; responsibility for periodic upgrading based on system or component failures; and, methods for incorporating revisions to Technical Specifications into procedures and the master progra (3) The above listed documents, relative to equipment control, were reviewed to establish that methods and responsibilities for equipment control have been defined and specifically to confirm that:
procedures have been established to specify that the operating staff grants permission to release equipment or systems for maintenance; equipment that is environmentally qualified is identified as such prior to maintenance and sufficient controls exist to ensure it is returned to that status upon reassembly; procedures and responsibility have been established for returning equipment to service; when testing of redundant components or systems is required by Technical
Specification, such testing is documented; measures have been established and responsibility has been assigned for determining when independent verification has been implemented correctly; and, revisions to Technical Specifications have been incorporated into procedures and included in the master progra (4) The above listed documents, relative to special processes, were reviewed to confirm that responsibilities have been assigned to assure that the requirements of the administrative controls will be accomplished and that the administrative controls for special processes have been established as follows: a requirement that only qualified personnel will be used; a requirement that a current file of special processes will be maintained to include qualification records of procedures and personnel; and, criteria to establish when the use of mock-ups or other special training will be require (5) The above listed documents, relative to cleanliness controls, were reviewed to verify that:
procedures have been developed for cleaning safety-related components and systems and that responsibilities for implementing this requirement has been established; procedures have been established for maintaining the cleanliness of previously cleaned systems and that responsibilities for implementing this requirement has been established; and, the cleanliness classifications of plant systems have been establishe (6) The above listed documents, relative to housekeeping controls, were reviewed to confirm that administrative controls and responsibilities for general housekeeping have been established and include defined housekeeping zones and control of housekeeping during work activitie b. In order to determine whether the maintenance program is being implemented in accordance with regulatory requirements and to evaluate the effectiveness of the program on important plant equipment and assess the ability of the maintenance staff to conduct an effective maintenance program, a selection of completed work request packages and associated documentation was reviewe The specific work request packages and associated documentation are recorded in the following subparagraph (1) The below listed current and historical, corrective and preventive, work order packages and reports were reviewed to determine whether:
the cause of the failure was evaluated and adequate corrective action was taken to reduce the probability of recurrence, if applicable; and, the procedures specified in the maintenance package were adequate for the scope of the maintenance performe Work Type Safety Unit Request Maintenance Related Work Description
56643A Preventive No Lubricate main turbine steam seal regulator
56654A Preventive No Lubricate turbine lift pump and couplings
64829C Corrective No Remove tape from pipe drain plugs, apply sealant and re-install plug
27365C Corrective Yes Repair flange leak
27524C Corrective Yes Repair threaded pipe cap leak
0546701 Corrective Yes Replace missing "U" bolt
55273A Preventive Yes Instrument and control battery 2CA service test
51708J Corrective No Cut out nipple from old valve and install in new valve
51709J Corrective Yes Cut out and replace valve
51713J Corrective Yes Cut out and replace valve
0541291 Corrective Yes Cut out and replace valve
0541241 Corrective No Cut out and replace valve
0515201 Corrective No Repair plug leak
51290J Corrective No Repair leak on limitorque operator
27955C Corrective Yes Repack valve
57612F Preventive Yes Disassemble and inspect valve
57032E Preventive Yes Sample lubrication and inspect limitorque operator 3* 19722C Corrective Yes Repair valve packing leak 3* 19731C Corrective Yes Repair valve packing leak 3* 57048A Preventive Yes Remove, inspect, repair as necessary and install R.C. pump seals 2* 57729B Preventive Yes Remove, inspect, repair as necessary and install R.C. pump seals 1* 56385 Preventive Yes Remove old valve diaphram and replace
3* 56384 Preventive Yes Remove old valve diaphram and replace 3* 053493 Corrective Yes Cut out and replace valve 3* 052798 Corrective Yes Cut out and replace valve
- Historical records (2) The above listed work request packages were also reviewed to confirm that:
required administrative approvals were obtained before initiating the work; limiting conditions for operation were met while the component or system was removed from service; approved procedures were used where the activity appeared to exceed the normal skills possessed by qualified maintenance personnel; inspections were made in accordance with the licensee's requirements, and qoality control records are complete; functional testing and calibrations, as necessary, were completed before returning the equipment to service; the licensee evaluated system failures; corrective and preventive maintenance records were assembled and stored as part of the maintenance history; the Measuring and Test Equipment (M&TE)
used was identified and in calibration; parts and materials used were identified; special processes were controlled and documented; and, system lineups were made and verified prior to return to servic In addition, the review of the historical work request packages, listed above, was accomplished to determine if the records were being adequately retained, that the records are available for review, are legible, are accurate, and complet c. The inspector observed the in progress maintenance activities listed belo These observations were conducted in order to verify the following:
maintenance personnel assigned understand the scope of the job; the procedures specified in the maintenance work request package were adequate for the scope of the maintenance being performed; required administrative approvals were obtained before initiating the work; inspections were made in accordance with the licensee's requirements, and quality control records were complete; special processes were controlled and documented; the mechanics were qualified for their respective tasks; supervisory oversight of the work was adequate; and the level of supervision for the work in progres Work Unit Request Activity Observed
51162J Fabrication of protective covers per commitment ID2583
51797J Welding of valve leak off pipe cap in preparation for installation of replacement valve
0502511 Installation welding of replacement 12" diameter elbow d. The below listed maintenance procedures were used to conduct the maintenance activities for the work request packages listed in subparagraphs b.(1) and c. abov The inspector reviewed these procedures in order to confirm that:
the procedure conforms to the licensee's administrative requirements, including format, approval, and control; the post-maintenance testing was appropriate for the repairs made; the inspection and hold points are identified in the procedure or in a documented plan and are based on a set of established guidelines; supplementary reference material such as drawings and technical manuals are adequate and controlled; the activity is described in sufficient detail; consideration is given to radiological, temperature, pressure, and electrical hazards, as appropriate to the circumstances; the provisions for fire protection, cleanliness, and housekeeping are adequate; appropriate instructions and quality control checks are included to verify that environmentally qualified equipment is properly protected against moisture intrusion when reassembled; and, the provisions for control of equipment, including lifted leads, jumpers, bypasses, and mechanical blocks are presen Procedure Number Title IP/0/A/3000/003 125 VDC Instrument & Control Battery Service Test and Annual Surveillance IP/O/A/3001/010 Maintenance of Limitorque Valve Operators MP/O/A/1200/001 Valves Adjusting and Packing MP/O/A/1200/009 Valve-Grinnel1-Diaphragm-Handwheel Operated-Disassembly and Reassembly MP/O/A/1200/080 Valves-Walworth-Swing Check-Disassembly and Reassembly MP/O/A/1210/004 Operator-Limitorque-SB/SMB-O Through 4/4T Disassembly, Repair, and Reassembly MP/O/A/1210/007 Operator-Limitorque-SMB/SB Series Removal and Replacement MP/O/A/1210/010 Operators-Limitorque-Preventive Maintenance MP/O/A/1210/019 Operator-Limitorque/Rotork-Operator Painting Procedure MP/O/A/1310/005 RCP Seal-Bingham-Type RQV875B-1-Removal
MP/O/A/1310/006 RCP Seal-Bingham-Type RQV875B-3 Repl acement MP/O/A/1720/010 System/Component Hydrostatic Test Controlling Procedure MP/O/A/1800/001 Tool & Materials Inventory Checklist On Open Safety Related Systems MP/O/A/1800/003 Flanges Torquing MP/O/A/1800/024 Grouting: Controlling Procedure For Safety Related Structural Grouting MP/O/A/1800/035 Concrete Anchor -
Installation MP/O/A/1800/048 Fittings/Piping -
Screwed -
Repair or Installation - QA Condition 1 MP/O/B/1800/048C Fittings/Piping -
Screwed - Repair or Installation -
Non QA MP/O/B/1800/072 Structural Steel-Miscellaneous Steel Non-QA-Welding Repair & Modification MP/O/A/1810/014 Valves and Piping -
Welded - Removal and Replacement -
Class A Through F MP/O/B/1810/015 Welding -
Piping and Valves -
Removal and Replacement of Class "G",
"H",
and QA Condition 3 MP/O/A/1840/008 Lubrication-Component-Bearings MP/O/A/1840/009 Coupling -
Lubrication MP/O/A/1840/038 Plant Components -
Miscellaneous MP/O/A/3019/005 Hangers -
Can Spring -
Removal Repair Installation Adjustment Locking &
Unlocking e. The inspector reviewed 35 maintenance personnel qualification records and a sample of training records for the personnel identified in the work requests listed in subparagraphs b.(1)
and c. abov These personnel were identified as having performed portions of the required maintenance activities in accordance with a specific procedure in the applicable work request packag This review was accomplished in order to assess the qualification and training, periodic retraining, and control of job assignments to individuals having a skill level appropriate to the specific maintenance activit In addition, the review of personnel qualifications was conducted to verify that at least one individual in each group was qualified to the work procedur This requirement is specified in each of the mechanical maintenance procedure Records of the below listed Measuring and Testing Equipment (M&TE),
that was used during maintenance activities, were reviewed to confirm the following:
the M&TE was in calibration at the time of use; the calibration of the M&TE can be traced to nationally recognized standards; the M&TE is properly stored, controlled, identified with a unique number, and labeled with calibration status; the error of the M&TE is less than or equal to the instrument being calibrated; and, the calibration history is kept up to dat Item -
Control Number Date Used Torque Wrench OCMNT 26972 5/5/90 Torque Wrench OCMNT 27436 5/11/90 Torque Wrench OCMNT 27327 5/15/90 Depth Mic OCMNT 27010 5/26/89 Torque Wrench OCMNT 27358 5/26/89 Pressure Gauge 0-300 30493 12/10/89 Pressure Gauge 0-5000 30584 11/20/89 g. Preventive Maintenance Program The licensee's preventive maintenance program is computerize The inspector discussed the program with licensee personnel and had the various program sections demonstrate From these discussions and the variety of demonstrated capability, the program appears to be very dynamic and combines the efforts of management and engineering in an effort to enhance plant operational safety and increase plant equipment reliability and availabilit The program will produce a master schedule on deman The program controls and regulates preventive maintenance performance schedules while focusing emphasis on detecting and rectifying degraded conditions prior to equipment failur The program provides timely responses and initiates proper actions based on Failure/Analysis/Trending reports provided by the maintenance management support uni The program is monitored daily with monthly reports furnished to local and general office managemen Any preventive maintenance action to plant production equipment may be considered for inclusion to the preventive maintenance progra Any other plant maintenance that is recurrent may be included under the programs standing work request program. The program contains a mechanism to identify overdue preventive maintenance work requests that are not completed within a predetermined time fram Equipment is reviewed and evaluated based on past history of repairs or replacements as recorded in the Nuclear Maintenance Data Base and the Failure/Analysis/Trending computerized module, and the Nuclear Plant Reliability Data Syste From the results of periodic reviews and engineering evaluation, the program is continually adjusted and updated as necessar h. Observations (1) During the review of work request package 0546701, the inspector noted that the package did not contain the design engineering justification needed to support the action taken. The inspector discussed this with the responsible engineer noted in the work request packag Apparently the engineering justification was inadvertently omitted from the work request package but was included in the Inservice Inspection package from which the work order package was initiate The inspector reviewed the
engineering justification and a copy of the justification was then inserted into the maintenance work request packag (2) While reviewing work request package 64829C for Unit 1, the inspector noted that the blanks in the work procedure were not filled in for the required post maintenance leakage inspectio There was a satisfactory test notation included in section VIII of the work request, dated 5/17/90, where functional verification and retests are usually noted, but it was not possible to tell if that entry applied to the post maintenance leak tes This discrepancy was brought to the attention of management and supervision and it was decided to require a reverification leakage test and to document the results in the proper place in the work procedur The reverification of the leak test has been included as a requirement in the work request, however, the leak test reverification had not been completed at the conclusion of this inspection due to the current condition of the syste The reverification will be completed prior to start up of the reacto (3) While observing in progress work being conducted to work request 51797J, on a non-safety related, Class G system valve, the inspector noted that some of the work being done was not included on the work reques In this case a cap was being welded on the end of the leak off pipe without the instructions being included in the work request. Questioning of the mechanics doing the work indicated that a verbal authorization for the work had been obtained from the planner. The inspector discussed this with the planner and the supervisor in charge of the work and concluded that the planner had given verbal authorization for the welding of the cap to the leak off pipe. The planner did include written authorization for the additional work in the request in the presence of the inspector. The inspector cautioned both the planner and the supervisor against future verbal authorizations and informed management of the possibility of future problems if verbal authorizations for work, even on non-safety related equipment, are being allowe All of the above inspector observed discrepancies were considered isolated cases and of minor importanc Within the areas inspected, violations or deviations were not identifie. Exit Interview The inspection scope and results were summarized on May 25, 1990, with those persons indicated in paragraph 1. The inspector described the areas inspected and discussed in detail the inspection result Although reviewed during this inspection, proprietary information is not contained in this report. Dissenting comments were not received from the licensee.