ML17251A381
| ML17251A381 | |
| Person / Time | |
|---|---|
| Site: | Ginna  |
| Issue date: | 11/28/1988 |
| From: | Blumberg N, Dev M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML17251A380 | List: |
| References | |
| 50-244-88-23, NUDOCS 8812080156 | |
| Download: ML17251A381 (18) | |
See also: IR 05000244/1988023
Text
-
U.S.
NUCLEAR REGULATORY COMMISSION
REGION I
d
Report
No.
50-244/88-23
Docket No.
50-244
License
No.
Licensee:
Rochester'as
& Electric Company
49 East
Av'enue
Rochester,
14649
Facility Name:
R.
E. Ginna Nuclear
Power Plant
Inspection At:
Ontario,
Inspection
Condu
d:
October 24-27,
1988
Inspector:
Approved by:
M. Dev,
PE,
Reactor
Engineer
N. Blumberg,
C ief
Operational
Programs
Section,
0
,
2B 88
da
e
(il~~/9
date
Ins ection
Summar
Routine
unannounced
inspection
on October 24-27,
1988
(Inspection
Report
No. 50-244/88-23)
R
f
f
R
Rf*
'
.
equipment
and materials.
Results:
The inspector identified concerns that the station
stockroom
had not
conducted
an inventory check of safety;related
equipment
and spare
parts in
the stockroom.
Several
such items were below the
minimum inventory level
required
as delineated
in the stockroom equipment
and spare parts cards,
and
no actions
were taken to replenish
them (paragraph
~ 2.3.4).
The station
management
has not resolved
the station corrective action report
No.
1833
(October
1987) which addressed
the lack of preventive
maintenance
for the
stored items.
Consequently,
the licensee
has not established
a list of spare
parts
and equipment
in the stockroom requiring preventive
maintenance
(PM), the
procedures
for performing
PM and
a
PM schedule
(paragraph 2.3.3).
Some
gA hold
items were found not segregated
from the
new consignments
in the station
receiving area
(paragraph 2.3.5).
The
gC semi-annual
surveillance
reports
(1988) reviewed did not sufficiently document the
scope
and the surveillance
activities performed
(paragraph
2.4).
The licensee
audit program implementation related to Bell Power Generation
Service Corporation quality controlled activities of the plant modifications
were determined to be adequate.
88i2080i56 88ii30
ADQCK 05000244
8
PNU
1.0
Persons
Contacted
DETAILS OF INSPECTION
Licensee
Re resentatives:
D. Bryant,
gC Engineer
J. Doyle, Site Engineer
(Contractor)
W. Hess,
Receiving Inspector
(Contractor)
J. Hotchkiss, Modifications Project
Engineer
M. Leyrer, Stockroom Foreman
- R. Marchionda, Training Manager
- R. Mecredy,
General
Manager Nuclear Production
- T. Meyer, Director gA/gC
K. Nassauer,
gC Engineer
- M. Shaw, Administrative Service
Manager
- S. Spector,
Superintendent,
Ginna Station
- B. Stanfield, Associate
gC Engineer
G. VanArtsdalen,
Project Engineer,
Maintenance
United States
Nuclear
Re ulatory Commission
(US
NRC)
- C. Marschall, Senior Resident
Inspector
- Indicates
those attended
the exit meeting
on October 27,
1988.
The inspector also contacted
other licensee's
technical
and
administrative
personnel
during the course of this inspection.
2.0
Recei t Stora
e and Handlin
of Eoui ment
and Materials
(Module 38702)
2.1
~Sco
e
The scope of this inspection
was to ascertain
whether the licensee
was implementing
a gA program relating to the control of receipt,
storage
and handling of equipment
and materials
conformance with
regulatory requirements,
licensee's
commitments,
and industry guides
and standards
listed in Attachment-l.
2.2
Pro ram Review and
Im lementation
The inspector
reviewed the licensee's
administrative
procedures
listed in Attachment-
1 for the control of receipt,
inspection
and
acceptance,
and handling of spare parts
and equipment at Ginna.
In
addition, Bell Power Generation
Service Corporation (Bell), the
licensee's
agent,
also receives,
inspects,
stores
and handles
site materials
and equipment
procured for plant modifications by the
licensee.
The licensee
reviews
and audits Bell's quality. control
activities on
a yearly basis to determine the adequacy
and effec-
tiveness of their gA program.
2.3
~Findin
s
2.3.1
Stora
e of Materials
2.3.2
The inspector
toured the licensee's
two indoor facilities
used for the storage of safety-related
replacements
and
parts.
These facilities were access
controlled
and
displayed the
names of the plant personnel
authorized to
requisition materials from the stockroom.
The storage
facility located in the auxiliary
building meets
Level
B
storage
requirements.
Racks with location designation
are
used for storage of spare'arts.
Two ovens for welding
rods are also located in this area.
They were found to
have
been recently inspected
and
displayed proper
identification and markings.
The inspector also toured
the receiving area
and the storage
faci lity of Bell
on-site.
The facility was adequately maintained.
Identification and Control of Materials
and Parts
The licensee's
stockroom uses
equipment
and parts
cards to
control the inventory of safety-related
items at Ginna.
In
addition, the stockroom also uses
a computerized
maintenance
information system
(HIS) to supplement
the
station inventory control.
The inspector discussed
the
use of the HIS with cognizant planning
and warehouse
personnel.
The inspector selected
three equipment
numbers,
one each for a temperature
element,
a level transmitter,
and
a pressure
transmitter using their unique equipment
identification numbers.
The status of the inventory could
not be verified using the HIS.
There is apparent
lack of
agreement
between
HIS and equipment inventory due to
partial data acquisition
and incomplete equipment
information.
The inspector verified that stored
spare parts
were
properly tagged
and identified.
However,
some
deficiencies
were identified.
In one instance,
the
inspector
noted that
a Potter Brumfield relay and Eberline
relays
had been identified by the
same part number
(6234),
even though their model, configuration
and functions were
different. In another
instance,
a
5
HP motor,
NEG-98441-79-1
procured in 1979 was recently transferred
to the stockroom from the field warehouse.
The stockroom
personnel
inspected
the consignment
and identified that
the motor specification did not meet the purchase
order
requirements.
On August 26,
1988 the
motor was put on gA
0
hold.
These
instances
indicate lack of proper inspection
and verification of the stockroom inventory.
The licensee
is aware of these
problems
and is evaluating corrective
actions
as part of the station g-list update
program to
improve identification, inspection
and storage of spare
parts
and equipment in the stockroom.
The inspector did
not have further question at this time.
Preventive
Maintenance
(PN) of S are Parts
Administrative Procedure
A-1304 provides for periodic
inspection
and maintenance
performed
on spare parts stored
in the stockroom which have special
requirements.
Administrative Procedure
A-1301 provides instructions for
maintenance
and inspection of material handling equipment
at Ginna.
The inspector discussed
with the licensee
representatives
the
PN activities for the stored
items
requiring
PM, specifically an
RHR pump motor
880C19252
stored in the stockroom.
Review of the stockroom inventory
indicated that this motor was not even listed in the
stockroom inventory list.
However,
based
on the review of
the maintenance
log and discussion with the cognizant
maintenance
and stockroom personnel,
the inspector deter-
mined that the electrical
maintenance
department
had
conducted
PNs for this motor but did not document the
activities,
and maintain records for lack of a
procedure.
Also, the licensee
had not developed
a list of
spare parts
and equipment in the stockroom which require
PM, nor had established
a
PM schedule to accomplish
such
activities. Discussion with the cognizant maintenance
personnel
indicated that the licensee initiated
a
corrective action report
(CAR-1833) in October
1987 to
address
these
issues.
However,
no prompt
actions
have
been taken to resolve the concerns
stated
in the
CAR, and
to institute
a
PN program for the spare parts
and equipment
in the stockroom.
The licensee
representative
stated that
the station maintenance
department
is currently coordinat-
ing with other disciplines at the site to finalize a
schedule
and establish
procedures
to implement
PM program
to the stock items.
Pending
implementation of the licensee's
PM program for the spare parts
and equipment in the
stockroom,
and verification of its adequacy
by the
NRC,
this item is considered
an unresolved
issue
(50-244/88-23-01).
Lack of equipment control
and retrievability was also
evident for
Q classified
Chain Falls
BKW-04 and
BKW-47 used
for station lifting and hoisting'activities.
These chain
falls were issued to the station maintenance
department
personnel
in July 1985
and
had not been
inspected,
as
required
by the station Administrative Procedure
A-1301
since then.
The stockroom personnel
stated
that the
mechanical
maintenance
department
had
been requested
to
retrieve the chain falls
and return them to the stockroom
for inspection
and certification so that
unqualified use
of the equipment for any safety- related activities could
be avoided.
The maintenance
department
had not responded
to the stockroom request
and
as such, the chain falls had
not been retrieved yet.
The stockroom foreman
has
escalated
action to retrieve them or otherwise declare
them
unusable
at the site.
The inspector did not have further
questions
at this time.
Stockroom Inventory
The inspector
reviewed the equipment
and spare parts
cards
and verified the inventory of selected
items in the
stockroom.
The spare parts cards
had identified minimum
and
maximum inventory
required for these
items.
Several
of these
items in
stock were below minimum required
inventory level
(see Attachment-1).
In another instance,
the inspector
noted that
some of the stock materials
and
spare parts
were not properly rotated.
These
spare parts
had
been in the station stock for several
years
and were
not used whi le the recently procured replacement
items
were issued for use.
These
instances
indicated that the
licensee
lacked proper control
and verification of
stockroom inventory,
and
an initiative to procure the
deficient items to replenish the inventory in a timely
manner.
The licensee
is currently evaluating corrective
actions to improve procurement activities.
Recei t Ins ection
The inspector reviewed receipt inspection documentation,
and
selected
nonconformance
reports
(NCRs) for material
deficiencies identified by the licensee
QC inspectors
and
the Bell
QC inspectors.
The licensee's
receipt inspection
log entries in several
instances
were found inconsistent:
Accept/Reject status of the materials
inspected
was not
identified; and applicable
and the status of
associated
dispositions
were not referenced
to indicate
when these
nonconforming materials
were accepted
by the
receipt inspectors.
A licensee
representative
initiated
corrective measures
to update the entries
and provided
documentation
to support the adequacy of the receiving
inspections.
The inspector also noted that the licensee
QA hold items
were not segregated
from the
new consignment
marked for QC
inspection,
in accordance
with the requirements
of ANSI
N45.2.2-1972Property "ANSI code" (as page type) with input value "ANSI</br></br>N45.2.2-1972" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process..
For example,
Part
No. 34256-244-4227,
HSIV
Stud was
on
QA hold since
Hay 2,
1988,
and Part
No.
NQ-10915-B-JD,
Valve Positioner since July 14,1988,
and
were kept in the receiving area awaiting disposition.
Lack of initiative on the part of the station engineering
department
and the maintenance
department
is an apparent
cause of delay in disposition of these materials.
A
licensee representative
stated that the
QA hold materials
will be segregated
and the station
QC group will followup
their dispositions with the cognizant station departments.
Pending disposition of these
QA hold materials to avoid
their inadvertent unqualified use, this issue is
considered
an unresolved
item (50-244/88-23-02).
2.4
QA/QC Interfaces
The licensee
QA group conducts audits of the station
activities of
receipt,
storage
and handling of equipment
and materials at Ginna
on
yearly basis.
An audit of these
areas
is scheduled for November
1988.
Based
on the review of the station
stockroom activities,
documentation
including audits
and discussion with cognizant
personnel,
the inspector determined that the
QA audits
lack in-,depth
review and verification of the stockroom activities.
The station
QC conducts surveillance of stockroom activities
on a
'emiannual
basis.
The inspector reviewed
a recent surveillance
report.
The report did not indicate the scope
and activities that
were covered
by this surveillance
report.
The licensee
representative
stated that
a checklist
has
been prepared
and the
inspectors
are
required to follow this checklist to perform
surveillances.
Subsequently,
a cognizant
QC engineer
reviews the
report,
and
upon completion of all required actions the report is
signed off and sent to the central
document control center.
The
inspector
noted that the surveillance report was in fact reviewed by
the cognizant
QC engineer
as indicated by the surveillance report
log.
However, the adequacy of the surveillance
could not be
determined for lack of adequate
documentation of the activities
performed.
Lack of sufficient documentation of the stockroom
surveillance
to delineate
the scope,
and the surveillance activities
performed is considered
an unresolved
issue
(50-244/88-23-03).
The inspector
reviewed the licensee
QA audits
( 1'isted in Attachment-1)
of Bell's procurement,
storage
and handling activities,
and overall
programmatic
compl.iance to Ginna station
QA requirements.
The audits
were properly coordinated,
and the audit, findings were comprehensive.
Bell had resolved
the audit findings and implemented
the required
corrective actions in
a timely manner.
2.5
Conclusion
Based
on the review of the licensee's
documentation
and activities
of receipt,
storage
and handling of equipment
and materials,
and
discussion
with the cognizant plant personnel,
the inspector
determined that certain activities were not adequately
controlled
and
properly implemented.
For example,
the
MIS which supplements
the
stockroom equipment
and parts cards for control of spare parts
inventory is not very useful for lack of complete data acquisition.
The licensee
had not established
a list of spare parts
and equipment
in the stockroom requiring preventive
maintenance
(PM), the
procedures,
and
a
PM schedule.
For lack of
PM procedure
and guide-
lines,
the
PM for RHR pump motor in the stockroom
was not documented
and records maintained.
Control of the material
handling
equipment
was also inadequate
as evidenced
by untraceabi lity of chain falls
which have not been
inspected
and certified for use
since
1985.
The licensee
lacks proper control
and verification of stockroom
inventory.
Some safety-related
items are below minimum required
stock inventory level
as delineated
in the equipment
and spare parts
cards,
and
no actions
were taken to replenish
them.
Also,
some
stock items were not properly rotated,
thus,
leaving the older items
still on the shelf while the
new replacement
items were issued for
use.
Review of a recent
semi-annual
QC surveillance
report of the
stockroom activities indicated that the report did not sufficiently
document
the
scope
and the surveillance activities covered
by this
surveillance.
The licensee's
material receipt inspection activity is adequate.
However,
in several
instances,
'the receipt inspection
logbook did not
reference
the
NCRs and associated
disposition for the nonconformances
identified by the
QC inspectors
during recept inspections.
QA hold
items
and
new consignment
assigned
for QC inspection
were found mixed
together
instead of kept being segregated.
Some of these
QA hold
items
have not been dispositioned
in a timely manner for apparent
lack of initiatives of the station engineering
support
and the
maintenance
department.
Review of the licensee
audits of Bell's quality controlled
activities at Gonna,
and discussion with the cognizant plant
personnel,
the inspector
determined that the receipt,
storage
and
handling of project related
equipment
and materials
were properly
conducted
by Bell personnel.
3.0
Unresolved
Items
Unresolved
items are matter about which more information is required in
order to ascertain
whether they are acceptable
items or violation.
Three unresolved
items
have
been discussed
each in paragraphs
2.3.3,
2.3.5
and 2.4.
4.0
Hang ement Heetin
s
The licensee
management
was informed of the scope
and purpose of the
inspection at the entrance
interview on October 24,
1988.
The findings
of this inspection
were discussed
with the licensee representatives
during the course of this inspection
and presented
to the licensee
management
at the exit interview on October 27,
1988
( See paragraph
1.0
,or attenoees
).
At no time during this inspection
were written materials
given to. the
licensee.
The licensee
did not indicate that any proprietary information
was involved within the
scope of this inspection.
ATTACHMENT-1
1.0
Procedures/Manuals/Instructions
R. E. Ginna Technical Specifications
R.
E. Ginna Final Safety Analysis Report
ANSI H18.7-1972, Administrative Controls for Nuclear
Power Plants
Packaging,
Shipping, Receiving,
Storage
and Handling
of Items for Nuclear
Power Plants
ANSI N45.2. 13-1977, Quality Assurance
Requirements
for Control of
Procurement
Items and Services
for Nuclear
Power Plants
Regulatory Guide 1.33, Revision 0, Quality Assurance
Requirements'Operation)
Ginna Station Quality Assurance
Manual
Procedure
A-401, Control of Procurement
Documents
Prepared
at Ginna
Station,
Revision
16
Procedure
A-701, Receipt
and Acceptance of Materials
and Parts,
Revision
12
1
Procedure
A-802, Identification and Marking of Accepted Materials,
Parts
and Components,
Revision
4
Procedure
A-1301, Maintenance
and Inspection of Material Handling
Equipment,
Revision
9
Procedure
A-1303, Storage
and Preservation
of Materials
and Equipment
at Ginna Station,
Revision
14
Procedure
A-1304, Storage of Materials Requiring Periodic Inspections,
Revision
3
Procedure
A-1501, Control of Nonconforming Items, Revision
7
Procedure
A-1502,.Nonconformance
Report,
Revision ll
2.0
Audit Reports/Surveillance
Reports/Nonconformance
Reports
(HCRs)
88-24:PB, Safety Related
Procurement Activities of Bell Power Generating
Service Corporation,
June
15-16,
1988
88-33:DH, Audit of Bell Power Generating
Service Corporation
Programmatic
Activities, August 17-19,
1988
Quality Control Report QCR-88-0836,
Schedule Surveillance
Quality Control Report
QCR-880968,
Purchase
Order Ho. HQ-10915-B-JD
NCR G-88-303 for PO No. NQ-11081-B-JD,
June
16,
1988
HCR G-88-310 for PO No. NQ-10930-B-JD,
June
30,
1988
NCR G-88-316 for PO No. NQ-10961-B-JD,
June
28,
1988
NCR G-88-378 for PO No. NQ-10636-B-JD,
September
12,
1988
NCR G-88-391 for
PO No. NQ-11069-B-JD,
September
30,
1988
2.3.4
Stock Inventory
Part
Ho. 5427,
Diaphragm, Quantity Available
1,
Minimum
6008, Packing,
1
9341, 3-Valve Manifold,
0
1003, 3/4" Globe Valve,
5
7021, Marker
0
Required
3
2
1
6
10
4
~