ML18033A609
| ML18033A609 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 05/20/1987 |
| From: | Hensley B TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML082340470 | List:
|
| References | |
| 40800, 40800-V04-R02, 40800-V4-R2, NUDOCS 8902150430 | |
| Download: ML18033A609 (85) | |
Text
EMPLOYEE CONCERNS SPECIAL PROG VOLUBLE4 MATERIALCON'I'ROL CATEGORY SUBCATEGORY REPORT 40800 TRAINING UPDATED ryoa isoY30 TVA NUCLEAR POWER
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Material Control Subcategory (Final)
TITLE:
Training REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 1
OF 38 REASON FOR REVISION:
Revision 1:
To Incorporate Available SRP Comments and To Incorporate MBN DNC Corrective Action Plan CATD 40800-WBN-01.
Revision 2:
To Incorporate hdditiona1 SRP comments.
PREPARED BY:
PREPARATION 5l PEER:
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SI ATURE SIGNATURE REVIEWS Dh E
C'ATE CONCURRENCES SIGNATURE APPROVED BY:
I DATE CEG-H f
SIGNATUR
~> P7 DATE ECS GER N/A TE MANAGER OF NUCLEAR POWER CONCURRENCE (FINAL REPORT ONLY)
DATE
<<SRP Secretary's signature denotes SRP concurrences are on files, 2092T
I
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 2 OF 38 TABLE OF CONTENTS Page 1.0 CHARACTERIZATION OF ISSUES 1.1 Introduction 1.2 Description af Issues 1.2.1 Warehouse Personnel/Clerks 1.2.2 Receipt Inspections 1.2.3 Persons Authorized to Approve Nuclear Power Stores Requisition - 575
- 2. 0
SUMMARY
2.1 Summary of Issues 2.2 Summary of Evaluation Process 2.3 Summary of Findings 2.3.1 Warehouse Personnel/CLerks 2 '.2 Receipt Inspections 2.3.3 Persons Authorized to Approve Nuclear Power Stores Requisition - 575 2.4 Summary of Collective Significance 2.4.1 Management Effectiveness 2.4.2 Employee Effectiveness 2.4.3 Technical Adequacy 2.5 Sumnary of Causes 2.6 Summary of Corrective Action 2.6,1 Warehouse Personnel/Clerks 2.6.2 Receipt Inspections 2.6.3 Persons Authorized to Approve Nuclear Power Stores Requisition - 575 10 10 10 10 10 10 10
TVA ENPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUNBER:
2 PAGE 3
OF 38 TABLE OF CONTENTS 3.0 EVALUATION PROCESS 3.1 Evaluation Nethodology 3.1.1 warehouse Personnel/Clerks 3.1.2 Receipt Inspections 3.1.3 Persons Authorized to Approve Nuclear Power Stores Requisition - 575 3.2 Requirements or Criteria Established for Individual Issues Page 12 13 IR2 3.2.1 Marehouse Personnel/Clerks 3.2.2 Receipt Inspections 3.2.3 Persons Authorized to Approve Nuclear Power Stores Requisition - 575 3,3 Justification of Evaluation Process 14 15 15 16 jR2 4,0 FINDINGS 4.1 Marehouse Personnel/Clerks 4.1.1 Generic 4.1.2 Site Specific-MBN 4.2 Receipt Inspections 4.2.1 Generic 4.2.2 Site Specific-MBN 4.2.2.1 Construction 4.2.2.2 MBN Power Stores 16 16 21 21 21 21 4.3 Persons Authorized to Approve Nuclear Power Stores Requisition = 575 4.3.1 Generic 4.3.2 Site Specific-MBN 31 31 31
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 4 OF 38 TABLE OF CONTENTS Page 5.0 COLLECTIVE SIGNIFICANCE 5.1 Significance of Each Issue 5.1.1 Construction Marehouse Personnel/Clerks 5.1.2 Receipt Inspections 5.1.3 Persons Authorized to Approve Power Stores Requisitions - 575 5.2 Significance of the Subcategory 33 33 34 34 35
- 6. 0 CAUSES S.l Warehouse Personnel/Clerks 6.2 Receipt Inspections 6,3 Persons Authorized to Approve Power Stores Requisition-575 35 1R2
)R2 1R2 7.0 CORRECTIVE ACTIONS 7 '
Corrective Actions Already Taken or Planned 7.1.1 Generic 7.1.2 Specific 7.2 Corrective Action Required as a Result of This Evaluation 7.2.1 Generic 7.2.2 Specific 36 36 36 38 38 38 8.0 ATTACHMENTS Attachment h - Subcategory Summary Table (Computer Printout):
List of concerns by concern number indicating safety relationship and generic applicability 38
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER'0800 REVISION NUMBER:
2 PAGE 5
OF 38 TABLE OF CONTENTS 8.0 ATTACHMENTS (continued) httachnent B - List of concerns by Issue/Element Attachment C - ERT/NSRS Investigation Report on IN-85-369-001 Attachment D - MBN Construction
Response
to IN-85-369-001 Page 38
Executive Summary Naterial Control Category Subcategory Report 40800 "Training" I.
SUNNARY OF THE ISSUES There were seven employee concerns addressed by this subcategory.
They were further divided into three issues to facilitate evaluation of similar concerns.
These issues were "Warehouse Personnel/Clerks,"
"Receipt Inspections" and "Persons Authorized to Approve Nuclear Power Stores Requisition-575."
II.
NAJOR FINDINGS The issue, "Warehouse Personnel/Clerks,"
addressed two concerns regarding, the lack of training for their respective positions within the MBN Construction D vision.
The evaluation found this to be not factual.
The evaluation did find isolated cases of'eficiencies in material handling and control but could not substantiate a program problem attributable to lack of training.
The NSRS/ERT report identified some discrepancies which have been addressed and corrected by MBN Construction or are being tracked for corrective action.
These discrepancies were determined to be isolated cases not resulting from a lack of training.'dditionally, Warehouse Personnel did not perform Quality Control activities.
The training program in the early years was not well defined and was not error free, but considering the deficiencies found versus the thousands of items handled, it functioned rather well.
The second
- issue, "Receipt Inspections,"
addressed four concerns expressed about material receiving, inspections.
These concerns addressed both Construction Warehouse and Power Stores with regard to the lack of training of receipt inspectors.
The evaluation of this issue determined that receipt inspection training existed and was conducted by the individual engineering units until the establishment of a separate Naterials Service Unit in 1982.
The evaluation of this issue determined that persons performing, receiving inspections were required to be trained and certified.
Records indicated that personnel performing this function were trained and certified from 1975 until the present.
The material issued prior to the training and certification (1975) was primarily non-quality-related.
The quality-related material (primarily re-bar) received and issued before certification, received a record search for discrepancies.
This search did not reveal any recurring problem 4334T Page 1 of 2
conditions.
The third issue, "Persons Authorized to Approve Nuclear Power Stores Requisition-575,"
addressed one concern about the knowledge of these authorized persons in regard to the completion of the requisi-tion form, if'hey were receiving the proper material, and if these persons needed training.
The evaluation determined that training was no required for people authorizing requisitioning of supplies or material.
III.
COLLECTIVE SIGNIFICANCE OF MAJOR FINDINGS In conclusion, the evaluation noted some problems which were corrected and some inconsistencies in certification of training which were caused by inattention to detail.
These type problems should be limited considerably with the revised procedures,
- programs, and auditing systems which are now in place.
The deficiencies and discrepant conditions determined through the NSRS/ERT/ECTG evaluations have been corrected or are being tracked for corrective action via the Tracking and Reporting of Open Items (TROI) system.
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Page 2 of 2
TVA EMPLO'EEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 FRONT MATTER BEV:
3 PAGE i OF viii Preface This subcategory report is one of a series of reports prepared for the Employee Concerns Special Program (ECSP) of the Tennessee Valley Authority (TVA).
The ECSP and the organization which carried out the program, the Employee Concerns Task Group (ECTG), vere established by TVA's Manager of Nuclear Pover to evaluate and report on those Of'fice of Nuclear Power (ONP) employee concerns filed before February 1, 1986.
Concerns filed after that date are handled by the ongoing ONP Employee Concerns Program (ECP).
The ECSP addressed over 5800 employee concerns.
Each of the concerns vas a
formal, vritten description of a circumstance or circumstances that an employee thought was unsafe, unjust, inefficient, or inappropriate.
The mission of the Employee Concerns Special Program vas to thoroughly investigate all issues presented in the concerns and to report the results of those investigations in a form accessible to ONP employees, the
- NRC, and the general public.
The results of these investigations are communicated by four levels of ECSP reports:
- element, subcategory,
- category, and final.
Element reports, the lowest reporting, level, vill be published only f'r those concerns directly aff'ecting the restart of Sequoyah Nuclear Plant's reactor unit 2.
An element consists of one or more closely related issues.
An issue is a potential problem identified by ECTG during the evaluation process as having, been raised in one or more concerns.
For efficient handling, what appeared to be similar concerns vere grouped into elements early in the program',
but issue definitions emerged from the evaluation process itself'.
Consequently, some elements did include onTy one issue, but often the ECTG evaluation found more than one issue per element.
Subcategory reports summarize the evaluation of a number of elements.
- However, the subcategory report does more than collect element level evaluations.
The subcategory level overviev of'lement findings leads to an integration of information that cannot take place at the element level.
This integration of information reveals the extent to which problems overlap more than one element and will therefore require corrective action for underlying causes not fully apparent at the element level.
To make the subcategory reports easier to understand, three items have been placed at the front of each report:
a preface, a glossaiy of the terminology unique, to ECSP reports, and a list of acronyms.
Additionally, at the end of each subcategory report vill be a Subcategory Summary Table that includes the concern numbers; identi.fies other subcategories that share a concern; designates nuclear safety-related, saf'ety significant, or non-safety related concerns; designates generic applicability; and briefly states each concern.
Either the Subcategory Summary Table or another attachment or a combination of the two will enable the reader to find the report section or sections in vhich the issue raised by the concern is evaluated.
TVh EMPLOYEE CONCERNS SPECIhL PROGRAM REPORT NUMBER:
40800 FRONT NhTTER REV:
2 PhGE ii OF viii The subcategories are themselves summarized in a series of eight category reports.
Each category report reviews the major findings and collective significance of the subcategory reports in one of the following areas:
management and personnel relations industrial safety construction material control operations quality assurance/quality control welding engineering h separate report on employee concerns dealing with specific contentions of intimidation, harassment, and wrongdoing will be released by the TVA Office of the Inspector General.
Just as the subcategory reports integrate the information collected at t element level, the category reports integrate the information assembled in all the subcategory reports within the category, addressing particularly the underlying causes of those problems that run across more than one subcategory.
h final report will integrate and assess the information collected by all
. of the lower level reports prepared for the
- ECSP, including the Inspector General's report.
For more detail on the methods by which ECTG employee concerns were evaluated and reported, consult the Tennessee Valley huthority Employee Concerns Task Group Program Manual.
The.-Manual spells out the program's objectives,
- scope, organization, and responsibilities.
It also specifies the procedures that were followed in the investigation, reporting, and closeout of the issues raised by employee concerns.
'TVA ENPLOXEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 FRONT NATTER REV:
2 PAGE iii OF viii ECSP GLOSSARY OF REPORT TERNS>>
classification of evaluated issues the evaluation of an issue leads to one of the following determinations:
Class A:
Issue cannot be verified as factual Class B:
Issue is factually accurate, but what is described is not a problem (i.e., not a condition requiring corrective action)
Class C:
Issue is factual and identifies a problem, but corrective action for the problem was initiated before the evaluation of the issue was undertaken Class D:
Issue is factual and presents a problem for which corrective action has been, or is being, taken as a resu1t of an evaluation Class E:
A problem, requiring corrective action, which was not identified by an employee
- concern, but was revealed during the ECTG evaluation of an issue raised by an employee concern.
collective si nificance an analysis which determines the importance and consequences of the findings in a particular ECSP report by putting those findings in the proper perspective.
concern (see "employee concern")
corrective action steps taken to fiz specific deficiencies or discrepancies revealed by a negative finding and, when necessary, to correct causes in order to prevent recurrence.
criterion
( lural:
criteria) a basis for defining a performance, behavior, or quality which ONP imposes on itself (see also "requirement").
element or element re ort an optional level of ECSP report, below the subcategory level, that deals with one or more issues.
em lo ee concern a formal, written description of a circumstance or circumstances that an employee thinks unsafe, unjust, inefficient or inappropriate; usually documented on a K-form or a form equivalent to the K-form.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 FRONT HATTER REV:
2 I
PAGE iv OF viii grouping of employee concerns.
~findin s includes both statements of fact and the iudtments made about those facts during the evaluation process; negative findings require corrective action.
issue a potential problem, as interpreted by the ECTG during the evaluation
- process, raised in one or more, concerns, K-form (see "employee concern")
evaluation judgment or decision may be based.
root cause the underlying reason for a problem.
~Terms essential to the program but which require detailed definition have been defined in the ECTG Procedure Manual (e.g., generic, specific, nuclear safety-related, unreviewed safety-significant question).
TVh EMPLOYEE CONCERNS SPECIhL PROGRAM REPORT NUMBER:
40800 FRONT MATTER REV:
2 PhGE v OF viii hcronyms hI hdministrative Instruction JILISC American Institute oX'teel Construction ANSI hSME hSTM BFN BLN CATD CCTS CEG-H CFR CI CMTR COC DCR DNC hs Low hs Reasonably hchievable American Nuclear Society American National Standards Institute hmerican Society of Mechanical Engineers American Society for Testing and Materials hmerican Melding Society Brows Ferry Nuclear Plant Bellefonte Nuclear Plant Condition hdverse to Quality Corrective hction Report Corrective Action Tracking, Document Corporate Commitment Tracking System Category Evaluation Group Head Code of Federal Regulations Concerned Individual Certified Material Test Report Certificate of Conformance/Compliance Design Change Request Division of Nuclear Construction (see also NU CON)
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 FRONT MATTER REV:
2.
PAGE vi OF viii DNE DNQA DOE DPO DR ECN ECP Division of Nuclear Engineering Division of Nuclear Quality Assurance Division of Nuclear Training, Department oi Energy Division Personnel Officer Discrepancy Report or Deviation Report Engineering Change Notice Employee Concerns Program ECP-SR Employee Concerns Program-Site Representative ECSP ECTG EEOC EMRT EN DES ERT FCR FSAR GET HCI HVAC INPO IRN Employee Concerns Special Program Employee Concerns Task Group Equal Employment Opportunity Commission Environmental Qualification Emergency Medical Response Team Engineering Design Employee
Response
Team or Emergency
Response
Team Field Change Request Final Safety Analysis Report Fiscal Year General Employee Training Hazard Control Instruction Heating, Ventilating, Air Conditioning Installation Instruction Institute of Nuclear Power Operations Inspection Rejection Notice
TVA ElPLOTEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 FRONT MATTER REV:
2 PAGE vii OF viii L/R M&AI MI MSPB NCR NDE Labor Relations Staff Modifications and Additions Instruction Maintenance Instruction Merit Systems Protection Board Magnetic Particle Testing Nonconforming Condition Report Nondestructive Examination NPP Nuclear Performance Plan NPS
-NSB Non-plant Specific or Nuclear Procedures System Nuclear Quality Assurance Manual Nuclear Regulatory Commission Nuclear Services Branch NSRS NU CON NUMARC OSHA ONP OMCP PHR PT QAP QCI Nuclear Safety Review Staff Division of Nuclear Construction (obsolete abbreviation, see DNC)
Nuclear Utility Management and Resources Committee Occupational Safety and Health Administration (or Act)
Office of Nuclear Power Office of Workers Compensation Program Personal History Record Liquid Penetrant Testing Quality,Assurance Quality Assurance Procedures Quality Control Quality Control Instruction
TVA ENPLOXEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 FRONT NATTER REV:
2 PAGE viii OF viii QCP QTC RIF RT SI SOP SRP SMEC
. TAS TVA TVTLC UT Quality Control Procedure Quality Technology Company Reduction in Force Radiographic Testing Sequoyah Nuclear Plant Surveillance Instruction Standard Operating Procedure Senior Review Panel Stone and Mebster Engineering Corporation Technical Assistance Staff Trades and Labor Tennessee Valley Authority Tennessee Valley Trades and Labor Council Ultrasonic Testing Visual Testing MBECSP watts Bar Employee Corcern Special Program Matts Bar Nuclear Plant Mork Request or Mork Rules Morkplans
. Preface,
- Glossary, and List of Acronyms for ECTG Subcategory Reports HISTORY OF REVISION REV NUNBER PAGES REVISED REASON FOR CURRENT REVISION 3
To clarify that one or more attachments will help the reader find where a particular concern is evaluated
.I
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
-40800 REVISION NUMBER:
2 PAGE 6
OF 38 1.0 CHARACTERIZATION 1.1 Introduction The seven employee concerns addressed by this subcategory report vere arranged into three distinct issues vith each issue comprising concerns which dealt vith identical or closely related concerns.
This arrangement vas to aid the evaluation process.
All the concerns vere specific to QBN and vere determined not to he applicable to other plants.
The three issues were delineated as follows:
1.1.1 Warehouse Personnel/Clerks 1.1.2 Receipt Inspections 1.1.3 Persons Authorized to Approve Nuclear Power Stores Requisition-575 1.2 Descri tion of Issues 1.2.1 Marehouse Personnel/Clerks There were tvo concerns expressed regarding the 1ack'f training for varehouse personnel/clerks.
Concern IN-85-369-001 stated that warehouse clerks are untrained and often mix safety and non-safety materials.
Concern IN-85-570-001 stated that varehouse personnel lack an indepth knowledge of material specifications and an indepth knowledge of how to handle the distribution of ASME code materials.
This concern also stated that there was a total lack of training and inferred that there was a problem with personnel attitude.
1.2.2 Receipt Inspections There vere four concerns expressed about receiving inspections.
Concern IN-85-606-001 stated that receiving inspections were not performed in an adequate manner by trained, experienced, or certified personnel from the beginning of MBN construction until the establishment of the Materials Service Unit in 1982. It also stated that the receiving activities performed before 1982 consisted of accountability verification only.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM
. REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 7
OF 38 Concern IN-85-145-001 questioned why WBN did not establish a
quality receiving unit prior to three years ago.
(The Receiving Inspection Unit was established in 1982).
Concern IN-86-011-001 questioned why there was not a
receiving inspection group in existence prior to April 1982.
The individual was also concerned that "Q" materials received prior to 1982 do not meet the acceptance criteria of purchase specifications and/or documentation/hardware verification.
It is probable they have been installed in the field.
Concern HI-85-077-N12 was identified by the Nuclear Regulatory Commission (NRC) during, their review of the Quality Technology Company (QTC) file.
The concern was that it appeared as if Power Stores personnel were doing receipt inspection of material and documentation for which they had not been properly trained.
1.2.3 Persons Authorized to Approve Nuclear Power Stores Requisition-575 There was one concern expressed pertaining to the training of persons authorized to approve Nuclear Power Stores Requisition-575.
Concern IN-85-412-001 stated that 200-300 people are authorized to sign "Power Store Requisition-575" for material at the warehouse, A large percentage of them do not understand how to fillout the requisition and are uncertain whether they are receiving the proper material.
This could result in the wrong, type or quality Level material being installed in the plant.
The concern questioned the large number of people now authorized to sign for material.
- 2. 0
SUMMARY
2.1 Summar of Issues The basic perceived problems expressed by the employee concerns in.
this subcategory are:
Warehouse personnel/clerks and receiving inspectors were not properly trained for their jobs.
TVh EMPLOYEE CONCERNS SPECIhL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 8
OF 38 Why was a receiving inspection unit not established at WBN prior to 1982?
hlso, did materials issued and installed prior to 1982 have the proper certification or documentation?
People authorized to approve Nuclear Power Stores Requisition 575s were not properly trained for their jobs.
2.2 Surmar of Evaluation Process The concerns addressed by this subcategory report were evaluated in accordance with the Material Control Evaluation Plan.
Because each element was evaluated independently, the evaluation process utilized varied somewhat with respect to the nature of each issue.
In
- general, the concerns relating to Warehouse Personnel/Clerks, Receiving Inspectors, and people authorized to approve Nuclear Power Stores Requisition-575 were, evaluated as follows:
Requested QTC to provide any additional information they could Reviewed applicable ERT/NSRS Reports to determine if these issues were addressed Zeviewed procedures to determine training requirements Reviewed pertinent training and inspection records Reviewed the NRC expurgated and NSRS unexpurgated files Conducted interviews with people knowledgeable in the areas of the concerns Concerns relative to receiving inspection unit at WBN before 1982 were evaluated by the above plus a search of Nuclear Regulatory Commission (NRC) violations and deviations for the years 1979 through 1982 for any NRC requirements for establishing a separate receiving inspection unit.
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I 2.3 Summar of Findin s
There were three issues raised by the various employee concerns contained in this subcategory.
The following is a summary of the findings for the three issues contained in this subcategory.
2.3.1 Warehouse Personnel/Clerks Training requirements for warehouse personnel/clerks were found in a memorandum dated March 16, 1971.
Interviews and reviews of personnel records documented on-the-job training.
hn investigation report on employee conc'em IN-85-369-001 issued by 'the Employee
Response
Team/Nuclear Safety Review
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 9 OF 38 Staff (ERT/NSRS) contained three NSRS recommendations for corrective action for concern IN-85-369-001'.
A memorandum from Guenter Wadewitz to R. P. Denise titled "Watts Bar Nuclear Plant - Request For Investigation/Evaluation" dated March 12, 1986, contained a construction response to IN-85-369-001 in which WBN construction addressed the three NSRS. recommendations.
The corrective actions have either been completed or are being tracked by a Corrective Action Tracking Document (CATD).
These corrective actions were taken to correct isolated findings and to enhance warehouse personnel's training at the election of DNC.
See summary of Corrective Action in Section 2.6.
2.3.2 Receipt Inspections It was determined that persons performing receiving inspections at WBN construction warehouse before the establishment of the receiving unit in 1982 were required to be trained and certified.
Training for WBN construction personnel was provided by the individual engineering units.
It was determined that receipt inspections were performed at the WBN construction warehouse prior to the initiation of a formal certification program for receipt inspectors.
Formal certification began in the early months of 1975
'here is an existing training and certification program for Nuclear Power personnel who perform receipt inspection at WBN Power Stores.
Receipt inspections at WBN-ONP were"governed by Standard Practice 4.1 (WB-4.1) and Administrative Instruction 5,2 (AI-5,2) from 12-06-77 to the present.
2.3.3 Persons Authorized to Approve Nuclear Power Stores Requisition-575 The approval of Nuclear Power Stores Requisition-575s by authorized personnel does not require special training.
Nuclear Power Stores personnel who issue material are required to be trained and certified.
Their responsibilities include verifying that the Nuclear Power Stores Requisition-575 contains the correct Quality Assurance (QA)
. level of the material issued when appropriate.
'VA ENPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUHBER:
40800 REVISION NUNBER:
2 PAGE 10 OF 38 2.4 Summar of Collective Si nificance 2.4.1 Management Effectiveness The findings in this subcategory revealed that management was dilatory in initiating necessary MBN site procedures to provide training and certification as required for Material Receipt Inspectors.
Training was not well defined or documented.
Both MBN Construction and MBN Power Stores were in operation apprazimately ten months before the establishment of site Receipt Inspection Training procedures.
It is noteworthy to mention that these two groups engaged in this "Learning Process" four years apart.
tR2 2.4.2 Employee Effectiveness Employee effectiveness is not applicable to this subcategory.
2.4.3 Technical Adequacy Technical adequacy is not applicable to this subcategory.
2.5 Summar of Causes The concerns resulted from a misunderstanding of the functions of warehouse personnel, confusing "Receiving" of materials with "Receipt Inspection" of materials and from questions regarding why the receiving inspection program changed in 1982.
Items identified in NSRS-report on concern IN-85-369-001 identified problems related to lack of attention to detail and not to lack of training of warehouse personnel.
IR2 2.6 Summar of Corrective Action 2.6.1 Marehouse Personnel/Clerks CATD number 40800-MBN-01 was issued to track open items in MBN construction response to concern IN-85-369-001 investigated by ERT/NSRS.
'VA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 11 OF 38 The Corrective Action Plan as proposed by MBN DNC and concurre'd with by ECTG is summarized below:
Standard Operating Procedures (SOP) for training of WBN warehouse personnel have been developed.
The initial training of all material clerks on the new SOPs has been completed.
The ledger system has been computerized.
The review of inventory material is in progress.
Identification and consolidation of material are being, accomplished at the present time.
Material that cannot be properly identified will not be used.
2.6.2 Receipt Inspections No corrective action was required.
2.6.3 Persons Authorized to Approve Nuclear Power Stores Requisition -575 No corrective action was required.
3.0 EVALUATION PROCESS 3.1 Evaluation Methodolo gl The various issues raised by the employee concerns within this subcategory were evaluated according to the Material Control Category evaluation plan.
Seven concerns were evaluated in this subcategory.
These concerns were grouped into 3 major elements as described in section l.
3.1.1 Marehouse Personnel/Clerks This element was derived from concern numbers IN-85-369-001 and IN-85-570-001.
The perceived problems were that warehouse personnel/clerks are untrained and often mix safety and non-safety materials.
The method used to evaluate these concerns is as follows:
A.
Nuclear Safety Review Staff/Employee
Response
Team (NSRS/ERT) investigation reports were reviewed to ensure the responses fully addressed the problem area.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 12 OF 38 B.
Quality Control Procedures vere reviewed and interviews with WBN construction warehouse supervision were conducted to determine training requirements for warehouse personnel/clerks.
C.
Reviewed NRC expurgated and NSRS unexpurgated files to determine if additional information was available.
D.
h se1ected number of MBN construction warehouse personnel/clerks were interviewed.
These included the warehouse Supervisor, Training Officer, Materials Officer, Materials Clerks, and Material Clerk trainees.
E.
A random sample of training records for MBN construction warehouse personnel/clerks was revieved.
F.
Information from the NSRS/ZRT report and fram the WBN construction response to concern number IN-85-369-001 relative to the mixing of safety and non-safety material was reviewed.
3.1.2 Receipt Inspections This element vas derived from concerns IN-85-606-001, IN-85-145-001, IN-86-011-001 and HI-85-077-N12.
The perceived problems were that receiving inspections were not performed adequately and vere not performed by trained, experienced or certified personnel before 1982.
Why was a
receiving inspection unit not established at MBN before 1982?
Material received before 1982 may not have met purchase specifications.
Power Stores personnel performed receipt inspection of material and documentation for which they had not been trained.
The method used to evaluate these concerns is as follows:
A, Quality Technology Company (QTC) was contacted to determine if there was additional information available on these concerns.
B.
Determined if ERT/NSRS reports were available for the concerns.
C.
Reviewed NRC expurgated and NSRS unexpurgated files to determine if additional information was available'
TVh EMPLOYEE CONCERNS SPECIhL PROGRhM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 13 OF 38 D.
h WBN construction response to concern IN-85-145-001 was reviewed.
E.
Training requirements for persons performing receiving inspections at the WBN construction warehouse before 1982 were determined.
F.
Training records of a selected number of persons performing receiving inspections before 1982 were reviewed.
G.
k random sample of personnel who performed receiving inspections at WBN construction warehouse was interviewed.
H.
A comprehensive effort was made to discover a requirement for establishing a separate materials inspection unit.
I.
"Receiving Reports,"
"Over, Short,
- Damaged, or Defective Reports,"
and "Non-Conforming Reports" were reviewed for material received that did not meet contract specifications and was subsequently installed in the field.
J.
Procedures were reviewed to determine training.
requirements for Nuclear Power personnel who perform receiving inspections at WBN Power Stores, K.
Interviews were conducted with WBN Power personnel to obtain information relating to training and certification for Nuclear Power personnel who perform receiving inspections or provided Technical Assistance for Receipt Inspections.
3.1.3 Persons huthorized to hpprove Nuclear Power Stores Requisition-575 This element was derived from concern IN-85-412-001, The perceived problems were:
Persons authorized to approve Power Stores Requisition-575 are not trained to complete the forms properly.
People who are issued material do not know if they have been issued the correct material and this, could result
'R2 in the use of the wrong Quality hssurance Level Materials.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER' PAGE 14 OF 38 There are too many people authorized to approve Power Stores Requisition-575.
The method used to evaluate this concern is as follows:
A.
QTC was contacted to determine if there was additional information available on this concern.
B.
Determined if ERT/NSRS Reports were available for the concerns.
C.
Reviewed NRC expurgated and NSRS unexpurgated files to determine if additional information was available.
D.
Nuclear Power procedures for the requirements for using Power Stores Requisition-575 were reviewed for limitations on the number of people who may be authorized to sign Power'tores Requisition-575.
S.
Nuclear Power personnel were interviewed to determine if a training program existed on the use of Power Stores Requisition-575, F.
A selected number of Power Stores Requisition-575s were reviewed ior compliance with procedures.
G.
Interviews were conducted with Power Stores personnel.
H.
Nuclear Power personnel were interviewed to determine what methods were used to ensure that QA level was maintained.
A visual inspection of the storage of some QA material was performed.
I.
QA personnel were interviewed and QA activity surveys were reviewed.
3.2 Re uirements or Criteria Established For Individual Issues 3.2.1 Warehouse Personnel/Clerks The criteria for training for warehouse personnel/clerks were in a memorandum from W. F. Baker dated March 16, 1971.
A training program to qualify warehouse clerical personnel fo" a newly established Materials Control Clerk, SB-4 position was in a memorandum from C. Boyce Corn, dated June 24, 1980.
(PLR800624016)
~
r
~
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 15 OF 38 3.2.2 Receipt Inspections The training requirements for people who performed receiving inspections at WBN construction warehouse before 1982 were defined in the Division of Construction Quality Control procedure DEC-QCP-l.ll, Revision 0, dated August 14, 1974.
DEC-QCP-l.ll, Revision 1, dated March 24, 1975, contained details of training, personnel certification, and certification in revised procedures.
DEC-QCP-l.ll, Revision 1 was approved by the WBN construction project manager and implemented at WBN but was not approved by corporate management.
WBN site procedure WBN-QCP-1.11, Revision 0 superseded DEC-QCP-1.11, on June 13, 1975.
Training requirements of this procedure were very similar to training requirements of DEC-QCP-l.ll, Revision 1.that was being, used at WBN.
The 0 erational ualit Assurance Manual (N-OQAM) dated March 1, 1973 stated that the Power Stores Supervisor is responsible for receipt inspections and that technical assistance shall be provided by the originator of the purchase request.
The Office of Power Quality Assurance Procedure 7'.1, dated July 7, 1976 required personnel performing receipt inspections to receive Quality Assurance Training and to be certified by the plant QA staff, Training requirements for Receipt Inspectors at WBN Power Stores are in WSM Administrative Procedure (AI)-5.2 which replaced WBN Standard Practice 4.1 (WB-4.1) in 1982, WB-4,1 was dated December 6, 1977.
No WBN site procedure for receipt inspection was found dated before December 6, 1977.
3.2 '
Persons Authorized to Approve Nuclear Power Stores Requisition-575 Training was not a requirement for persons authorized to approve Nuclear Power Stores Requisition-575.
There was no limitation on the number of people who could approve WBN Power Stores Requisition-575,
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 16 OF 38 3.3 Justification of the Evaluation Process The concerns in this subcategory report (Training) questioned the adequacy and lack of training for WBN Construction warehouse personnel/clerks, for receipt inspectors in both WBN Construction and Nuclear Power, for WBN Power Stores personnel who issue
The evaluation process was designed to determine the training requirements for personnel who performed the above mentioned activities.
Review of procedures and records and interviews with knowledgeable individuals were conducted to gather the information contained in this subcategory evaluation report.
- 4. 0 FINDINGS 4.1 Warehouse Personnel/Clerks 4.1.1 Generic Not applicable.
4.1.2 Site-Specific -
It was determined that. training requirements for WBN warehouse clerks, prior to 1980, were contained in a
memorandum dated March 16,
- 1971, from W. F. Baker, Chief, Construction Accounting Branch - "Recruitment and Training Program - Division of Construction."
The progress of individual employees in training was recorded by means of service review.
On June 24,
- 1980, C. Boyce Corn, Personnel Officer, Division of Construction, issued a memorandum, "Consideration of Warehouse Clerk-Trainees for Positions in Engineering Organizations,"
which was a training program to qualify warehouse clerical personnel for the newly established Materials Control Clerk, SB-4 position.
No other requirement for formal training for warehouse personnel/clerks was found.
No requirement for certification of warehouse personnel/clerks on the use of quality control procedures was found during this evaluation.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 17 OF 38 Eight interviews conducted with WBN construction warehouse personnel revealed that their training consisted primarily of on-the-job training.
The individuals interviewed were satisfied with their training with one exception.
This person was the same working level as the people performing receiving and could not remember being, assigned to an experienced clerk for training.
This person thought that clerks were not given enough responsibility and that this person should have received training on procurement,
- pricing, and transmitting receiving documents.
The only training record found for the WBN warehouse personnel/clerks prior to 1982 was the employee service review (TVA Form 3031) which contained the number of hours of on-the-job training received by the employee in order to be eligible for a promotion from SB-2 to SB-3.
An investigation was performed and a report prepared by the Employee
Response
Team (ERT) on employee concern IN-85-369-001 - "Warehouse clerks are not trained and often mix safety and non-safety material."
The ERT report (see attachment D) concluded that the concern was "substantiated,"
The deficiencies on which the conclusion was based were as follows:
Lack of knowledge of Material Control Clerks about QA requirements as they relate to the receipt, storage and handling of materials.
The lack of an established program for training of Material Control Clerks prior to 1980.
The common practice of having two trainees teamed together instead of one experienced clerk and one trainee teamed together during the 1980 Training Program.
The lack of formal training, in procedures prior to 1980.
The lack of formally issued and controlled procedures to describe the activities of Materials Control Clerks.
The current lack of adherence to the established training program requirements, The lack of material separation (safety and non-safety) prior to 1977-1979 timeframe.
TVh EMPLOYEE CONCERNS SPECIhL PROGRhM REPORT NUMBER:
40800 REVISION NUMBER:
2 PhGE 18 OF 38 The uncontrolled storage of material in the "DC Construction" and Engineering Cable" areas.
The misidentification of items in stock.
the lack of identifica~on of items in stock.
The mislocation of items of stock.
The ERT report also contained a list of nine (9) items that they noted as being discrepant.
Those items were as follows:
Item 1.
1/2" ball valve, Sh479-316 SM 600'. Mark 37M2061218 2.
14" sch 140 pipe, 0'2809-1-2
~ HT Lot 472376 Discre anc Stored in non-safety location.
HT Mismarked as hSTM h312-376 when material was hSME Sec III Class I 3.
Concentric
- Reducers, HT Code hEh 4.
Flange, Orifice Union, HT //216841-MHh 5.
I Beam 5" x 14.75,-
HT i/1815151 6.
Piping Material Yard 01B-6, Yard fPlC-5 7.
The roof of Building D-6 Yard Nl Failed with water Stored in wrong location sarong HT number.
Should be 181S151 Uncapped or ends split Brace of roof resting on piping material 8.
I Beam in uncontrolled D.C.
Laydown area identified as PM/Qh/04 R 551661, 10' 10" X 1/2",
h500 Gr B,
HT 77H14 9.
Non-conforming cable-various types.
Completely uncontrolled Uncontrolled The NSRS prepared three recommendations for VBN action/disposition for employee concern number IN-85-369-001, Those recommendations were as follows:
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 19 OF 38 Q-85-369-001-01:
"Warehouse Operations" The deficiencies in segregation,
- labeling, and storage of materials identified in this report need to be corrected via a quality assurance document.
Q-85-369-001-02:
"Training of Warehouse Clerks" Warehouse clerks should be trained in the applicable QA requirements of their jobs.
This training should be formal, documented, and completed under the QA program.
,Q-85-369-001-03:
"Adequacy of Issued Materials" Since warehouse clerks were not properly trained, materials were found mislabeled and mislocated; an evaluation of the adequacy of material issued needs to be made and documented under the QA program.
IR2 I
WBN construction prepared a response to the NSRS recommendations.
In response to recommendation Q-85-369-001-01 "Warehouse Operations,"
WBN Construction listed the corrective action taken for the nine items that the ERT report listed as being discrepant.
This ev'aluation verified that those actions had been completed.
The construction response stated that 486 items had been selected at random from ledger cards and checked for proper location and proper identification.
Only 1.9 percent of the sample could not be accounted for.
The construction response stated that material with ASME marking was stored in an ASTM location (see Attachment D, page 5 of 9, sections 10.b and 10.c) because that was its intended
- uses, IR2 In response to NSRS recommendation Q-85-369-001-02
- "Training of Warehouse Clerks," the response stated the intent of the training program for warehouse clerks.
It stated that prior to 1980, the training was as described in W. F. Baker's memorandum to Those listed dat'ed March 16, 1971.
WBN Construction felt that their training program could be strengthened and committed to do so.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 20 OF 38 In response to g-85-369-001 "Adequacy of Issued Material," construction took exception with the concern that a lack of training for the warehouse clerks resulted in mislocated and mislabeled material.
The response stated that this issue is not the training of the clerks but the controls on procurement,
- receipt, and installation.
A QC Inspector assists with the receipt of materials.
The inspector verifies the heat number.
Inspectors perform installation inspection including cable inspection.
iJBN construction listed twelve actions they would take to enhance the process.
They prepare a written response every two weeks to report their progress on these items to the Director of Nuclear Construction.
These items will also be tracked by the Employee Concern Task Group.
Eleven items were selected from the WBN warehouse ledger book for a survey on the storage of safety and non-safety material.
All items were found in the warehouse at the location taken from the ledger book.
No additional mixing of safety and non-safety material was found by this evaluation.
==
Conclusions:==
Training requirements and training methods for warehouse personnel/clerks were not well defined.
Training, ior warehouse clerks prior to 1980 existed in the form of on-the-job training based on a memorandum by M. F. Baker, dated March 16,
- 1971, as evidenced by observation of training schedules on Personnel Service Reviews (TVA Form 3031).
The training was informal and no formal training records for WBN warehouse clerks exist for the time prior to 1982.
Formal training records after 1982 indicated training on procedures, Requirements for personnel certification on the procedures did not exist, The training program for Materials Clerk, established in 1980, was for the purpose of preparing warehouse clerks for a newly created SB-4 po'sition.
On-the-job training was the primary training method for this program according to the material clerk interviews.
Only one of eight MBN construction warehouse material clerks interviewed indicated a dissatisfaction with the training received.
The ERT Report on concern number IN-85-369-001 identified a problem with 'mixing of safety and non-safety material which was an isolated incident which involved one safety-related valve that was checked out of the warehouse and then returned to the warehouse and stored in a
]R2 non-safety-related storage area.
WBN - Office of Constru'ction addressed the problem and has corrected it.
A survey on the storage of safety and non-safety material was conducted and found no other deficiencies.
No additional problems with the mixing of safety and non-safety materials were identified during this evaluation.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 21 OF 38 The final check for the installatibn of the proper material is the field inspection performed by the QC Inspection Unit.
No requirement for certification of warehouse personnel/clerk on the use of Quality Control Procedures was found during this evaluation.
WBN - Office of Construction response to employee concern number IN-85-369-001 recognized that their training program could be strengthened
[by enhancing the training program although this training is not required and is not associated with the Quality
. As'surance Program]
and construction committed to a formalized training program with written exams pending approval by the Division of Personnel, Other problems identified by the ERT/NSRS report were adequately addressed by the WBN response to concern IN-85-369-001.
Corrective actions have been completed or are being tracked by CATD number 40800-WBN-01.
I IR2.
I IR2 This was found to be a Class A issue.
4.2 Recei t Ins ections 4.2.1 Generic Not applicable'.2.2 Site-Specific - WBN 4.2.2.1 Construction The expressed concerns relating to receiving inspections applied to material received by the WBN construction warehouse before 1982.
The concerns were that the receipt inspectors were not trained and why was no separate Receipt Inspection Unit established at WBN Construction Warehouse before 1982.
Quality Technology Company (QTC) provided a copy of a IR2 WBN construction response to concern IN-86-011-001.
The response stated that WBN construction had always had individuals assigned to -receiving inspection and this evaluation agreed with the response.
It was determined that persons performing receiving inspections at WBN construction warehouse before 1982 were required to be trained and certified.
Quality control procedure DEC-QCP-l.ll, Revision 0, "Quality Assurance Training," dated August 14,
- 1974, defined the approach for formal training of construction site personnel in QA and control
TVA EMPLOY'EE CONCERNS SPECIAL PROGRAN REPORT NUNBER:
40800 REVISION NUMBER:
2 PAGE 22 OF 38 requirements.
However, it was not until QC procedure MBN-QCP-l.ll, Revision 0, was issued on June 13, 1975, that details of training and personnel certification were included in the procedure.
MBN-QCP-l.ll, Revision 2, was in effect until April 1982.
Training records obtained for ten individuals performing receiving inspections at MBH construction warehouse before 1982 consisted of Personnel Certification Records retrieved from the construction QA storage vault.
These records listed the QC Procedures to which the individual had been certified.
The records dated back to the early months of 1975.
MBN-QCP-1.11 required training, and personnel certification on applicable QC Procedures before performing the activity.
DEC-QCP-1.11, Revision 1 contained provisions for certification in revised procedures.
The QA unit reviewed revised procedures and determined if re-certification was required. If re-certification was required, QA notified the Constructi'on Engineer.
The individual engineering units provided training and then QA performed re-certification.
During an interview, a
former QA unit supervisor said that this procedure was used for re-certification on revised procedures.
Certification records showed that re-certification to revised procedures had been performed at MBN.
Interviews indicated that before the issuance of DEC-QCP-l.ll, Revision 0, "Quality Assurance Training " dated August 14,
- 1974, the engineering units provided training within the individual units.
The training (QCP-1.6) consisted of discussion and on-the-job training.
No records of this training were found.
DEC-QCP-1.11.
Revision 0, did not provide details for training and personnel certification on the use of QC Procedures.
MBN-QCP-l.ll, Revision 0, dated June 13,
- 1975, contained details for training and certification, Attachment A to MBN-QCP-l.ll was a personnel certification record.
Interviews and a failure to find personnel certification records on the use of QC procedures before early 1975 indicated that there was not a program for personnel certification before 1975.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER'0800 REVISION NUMBER:
2 PAGE 23 OF 38 Receiving reports obtained from the Records Information Management System (RIMS) verified that some permanent QA material was received before a
formal QA Training Program with personnel certification was established.
Much of the early QA material received was rebar.
A search of procedures, interviews with the past and the present supervisors of the Materials Inspection
- Unit, a search of NRC violations and deviations for the years 1979 through 1982, and an interview with an engineer from the Nuclear Licensing Branch in Knoxville did not reveal a requirement for establishing the Materials Inspection Unit as a
separate unit. Material receiving inspections existed before 1982.
The receiving, inspections were the responsibility of the individual engineering units who were responsible for the material.
Receiving reports were signed by the engineering representative performing the inspection.
QC Procedure DEC-QCP-1.6, "Receiving Inspections,"
was issued on January ll, 1974.
Training records indicated that training on DEC-QCP-1.6 was provided by the Civil Engineer Unit as early as February 14, 1975 with QA certification on DEC-QCP-1.6 following on March 6, 1975.
This same record contained certification to revisions on DEC-QCP-1.6.
Training records for the Electrical Engineering Unit showed training and certification on DEC-QCP-1.6, on March 24, 1975 and March 26, 1975.
A review of seven "Over, Short,
- Damaged, or Defective Reports,"
(OSD or D) was made.
The review of the OSD or D reports revealed that the material receiving inspectors had detected the following problems:
The wrong material,
- shortage, substitution, heat code letters illegible, mill certifications did not conform to specification and incomplete certification.
Eleven receiving reports (TVA Form 209) for QA material were reviewed to determine if documentation was provided with the material.
All eleven 209s listed Certificate of compliance or Certified Material Test Reports as being received with the material.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 24 OF 38 Eight nonconforming reports (NCRs) written for material that did not meet contract specifications were reviewed.
The NCRs indicated that receiving inspections were being performed before 1982.
The OSD or D Reports were written between October 4, 1975, and May 25, 1979.
The receiving, reports were written between May 15,
- 1973, and October 6, 1981, and the nonconforming reports were written between November 4, 1975 and April 28, 1981.
hn interview with a cognizant receiving inspector revealed that material without proper documentation had been installed in the field on at least one occasion.
This resulted in the writing of NCR 6069 when it was discovered that the Certified Material Test Report did not reflect the heat-treated condition as required for tubing that was received at MBN in March 1979.
The problem was not discovered until 1985 when some of the material was transferred to Sequoyah Nuclear Plant (SQN) where the error was found.
The material was acceptable and the correct documentation was provided by the supplier.
Further evaluation was made on the adequacy of the receiving inspections at MBN construction warehouse before 1982.
Twenty-two NCRs written 'against installation between March 6, 1975, and October 30, 1978, were reviewed to see if improper material was accepted by receipt inspection and installed in the field.
Two of the twenty-two NCRs were for material that should have been caught by the receiving inspection, NCR 852R was written because two beams did not have the proper heat numbers stenciled on them.
NCR 1002R was written because the vendor sent two relays that did not meet the requirements specified in the procurement
- document, 4.2.2.2 MBN Power Stores The QTC expurgated file f'r concern HI-85-077-N12 indicated that WBN Power Stores personnel were receiving material for which they had not been trained as opposed to field Quality Engineering (QE) people performing receipt inspection.
r TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 25 OF 38 Part III, Section 2.2 of the 0 erational ualit Assurance Manual (N-OQAM) dated March 1, 1973 was reviewed and it stated that the supervisor of the Power Stores Unit at the nuclear plant is responsible for receipt inspection and that assistance of a technical nature shall be provided to the Power Stores Unit by the originator of the purchase request to verify acceptability of the shipment.
The TVA Office of Power Quality Assurance Procedure 7.1 (OP-QAP-7.1) Revision 0, dated July 7, 1976 stated that the Division of Power Production through the Power Stores Unit Supervisor at the nuclear plants is responsible for the receipt and inspection of safety-related materials and that personnel performing, receiving inspections shall receive Quality Assurance training and be certified by the plant Quality Assurance Staff.
MBN Power Stores was initially staffed approximately February 13, 1977.
A Receipt Inspection Report dated April 12, 1977 was obtained indicating that some material was being received within two months after the initial staffing of MBN Power Stores.
The report referred to Administrative Instruction 11 (Al-ll),
No MBN AI-11 could be retrieved but an AI-ll for Sequoyah Nuclear Plant, Material-Recei t
~Ina ection.
naa obtained.
nn inteceiee indicated that the Receipt Inspection at MBN could have been made to the specifications of the SNP procedure since the two plants were working together at that time but the interviewee was not certain because of the long timeframe involved.
A copy of a gA Certified Recei t Ins ection List dated February 23, 1978 containing a list of personnel that was trained to the requirements of MBA84 was obtained.
(It is believed that MBA84 was a Matts Bar Standard Practice because a copy of another Matts Bar Standard Practice MBA36 dated March 22, 1977 was obtained);
- however, the Document and Control Unit has not been able to retrieve a copy of MBA84.
'VA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800
'EVISION NUMBER:
2 PAGE 26 OF 38 During the timeframe from February 1977 to December 1977, there were four people who performed receipt inspections at WBN Power Stores,
- One individual had worked in Power Stores at a steam plant, had worked in the Chattanooga Power Stores Classification
- section, had been assistant supervisor at a TVA nuclear plant and had been Power Stores supervisor at a steam plant bef'ore coming, to Watts Bar Nuclear Plant.
He had approximately 28 years experience in Power Stores work.
Another individual had worked in a TVA construction warehouse, Power Stores at two steam plants, and the Chattanooga Power Stores Classification Section before coming to MBN Power Stores.
He had approximately 15 years experience in Power Stores.
Another had served as a storekeeper f'r three years in the U.S. Navy, worked eight years in materials in private industry and worked more than four years in Power Stores at a TVA steam plant before coming to MBN Power Stores at the top TVA grade level for a storeroom clerk.
The other person worked five years at a TVA steam plant before he.
came to WBN Power Stores at the top TVA grade level for a storeroom clerk.
The earliest Watts Bar Nuclear Plant procedure for Receipt Inspection that was retrieved was Watts Bar Standard Practice 4,1 (WB-4.1) dated December 6,
1977.
MB-4.1 delineated the requirements and plant responsibilities of plant personnel for receipt of material.'The Power Stores Unit Supervisor was responsible for the receipt of materials.
The items received were to be checked against the packing list or shipping ticket by part number,
- tags, stampings, markings, etc.,
which shall agree with the TVA purchase contract or work order authorizing procurement.
The inspection shall be conducted by Power Stores personnel with assistance of a
'echnical nature provided, as needed, by the originating, section of the purchase request.
The originator of the purchase request or his representative shall participate in the receipt inspection for materials assigned Quality Assurance Level I and Level II substituted (a replacement part or component not identical to the purchased part or IR2 component)
.items.
Criteria f'r receipt inspection of these Level I and Level II items were contained in the Standard Practice MB-4.1.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 27 OF 38 Training and Certification Records (TVA Form 1453) were available for Power Stores personnel dating back to February 21, 1978.
QA provided training and performed certification.
Personnel from the Engineering, Units provided technical assistance for receipt inspection for QA Level I and Level II substituted items.
An interview with a mechanical engineer who had provided technical assistance for receipt inspections revealed that he had not received formal training and certification for receipt inspection but that he had informal training on the procedures.
This training was provided by the individual engineering unit and that he had some on-the-job training provided by his supervisor before he performed the task individually.
An interview with an Instrumentation General Foreman who was the initial Instrument Mechanic Foreman on.
the job revealed that he did not have any formal training for providing, Technical Assistance for Receipt Inspection but said that he depended on his background and vendor manuals.
He has a technical background'n instrumentation.
An interview with a Senior Instrument Mechanic Foreman who had provided technical assistance for receipt inspections revealed that he did not receive formal training, but he did recall that he had received informal and on-the-job training.
He also said that he ordered the materials, verified the correct material at time of receipt and if he had a
problem he would also go to the field and look at the part being ordered.
He would also have the vendor verify substitution.
The Receipt Inspection section of Matts Bar Standard Practice 4.1 (MB-4.1) was replaced by Administrative Instruction 5.2 (AI-5.2) on May 25, 1982.
AI-5.2, Revision 12 dated April 30, 1986 was reviewed.
From this it was determined that receipt inspection for QA Level I and II items, and QA Level III items that require the vendor to have an NQAM, Part III, Section 2.1, Appendix E, Attachment 6,
COC program, and ECN material that has 10 CFR 21 Applicable status (ezcept for onsite transferred items addressed in paragraph 5.5), shall be performed by QC inspectors who report to the plant QA staff supervisor.
Certified Power Stores clerks shall perform receipt inspections for procured items other
~ TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 28 OF 38 than those listed above.
WBN Power Stores receiving inspectors must be trained, certified, and recertified every year not to exceed 18 months, The QA unit was involved in the re-certification process.
Superceded revisions of AI-5.2 and WBN Standard Practice WB-4.1 were reviewed which disclosed that AI-5.2 replaced WB-4.1 in 1982.
Interviews were conducted with two people who performed receipt inspections at WBN Power Stores after, AI-5.2 became the governing document and Quality Control (QC) became responsible for Receipt Inspections for Quality Assurance Level I items, Level II substituted items, Level II items to which Part 21 applies and for ECN material to which Part 21 applies and which is shipped from the vendor to.
1R2 Nuclear Power.
These people received training at the Power Operations Training Center (POTC) and then received on-the-job training before they were certified by the Quality Assurance Unit.
Both felt that the training was adequate but one indicated that more extensive training would be beneficial.
Technical assistance when requested is provided by the Engineering Unit responsible for the material.
Both individuals stated that the technical assistance IR2 they had received was adequate.
1 Interviews with a WBN Power Stores Materials Officer revealed that the clerks were required to complete a
training course consisting of 960 hours0.0111 days <br />0.267 hours <br />0.00159 weeks <br />3.6528e-4 months <br /> of on-the-job training and 40 hours4.62963e-4 days <br />0.0111 hours <br />6.613757e-5 weeks <br />1.522e-5 months <br /> of formal training.
A portion of this training was devoted to receipt inspection.
Training and certification records were observed for the time period from February 1978 to the present time.
He said that QA was always responsible for certification of the clerks and that clerks had never actually received any QA Level I material or any material which was 10 CFR 21 applicable without technical assistance.
During 1976-1977, before the establishment of a QA group on site, section supervisors received all materials they had ordered.
NOTE:
The statement relating to section supervisors receiving the material came from interviews.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:, 2 PAGE 29 OF 38 Procedure WB-4.1 dated December 6, 1977, stated that the inspection shall be conducted by Power Stores personnel with assistance of a technical nature provided as needed by the originator for materials assigned QA Level I and Level II substituted items.
Two Corrective Action Reports (CAR) were written pertaining to piece part substitution for Class-1E environmental requirements.
Past records were reviewed for compliance and according to the interview with an Instrumentation General
- Foreman, no rework was required in his section as a result of the Corrective Action Report.
Some receipt inspection reports for material received at WBN Power Stores during the years 1977 through 1982 were reviewed.
Thirty-seven reports were reviewed and the Quality Assurance Level of the material recorded.
Of these thirty-seven reports, only two were for QA Level I material.
The QA, Level I material was received after training and certification of receipt inspectors had been implemented.
On another occasion forty-four receipt inspection reports were reviewed.
Only one of these reports was for QA Level I material.
Both reviews were random reviews.
The Watts Bar Power Stores N3 log which is a listing of nonconforming items of QA Level I and Level II material that required traceability was reviewed.
There were seventeen
"(17) nonconforming items (NCI) written by WBN Power Stores during 1977, which indicates the Receipt Inspection Program was identifying nonconformances.
==
Conclusions:==
I.
WBN Construction Warehouse A formal QA Training Program was not documented before DEC QCP-l.ll, Revision 0, dated August 14, 1974.
Personnel certification records in the use of QC Procedures dated back only to early 1975.
Receiving inspections of permanent material were performed at WBN before the establishing of a formal tr'aining and certification program.
There was no requirement for establishing a separate Materials Receiving Inspection Unit before 1982.
Interviews and research indicated that material Receiving Inspections performed before 1982 checked purchase specifications, documentations, and identified nonconformances.
These inspections were not just an accountability check.
0
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER' PhGE 30 OF 38 Some apparent errors were made during the receiving of material at the MBN construction varehouse, but there vere additional means to ensure installation of the correct material such as QC field verification of material and system valkthrough before transfer.
The receiving, inspection errors evaluated in this report were caught at MBN construction except for one case of improper documentation.
Even though research indicated that some material was received improperly at MBN construction warehouse before 1982, this evaluation did not find evidence to conclude that Receiving Inspection Program before 1982 vas not adequate.
MBN Power Stores Office of Power Quality Assurance Procedures 7.1 dated July 7, 1976 required personnel performing, receipt inspections to receive Qh training and to be certified by the plant Qh staff.
Some receipt inspections were performed at MBN Power Stores during the early evolution of the MBN Power Stores before training and certification were provided by the QA staff and before MBN Procedures vere developed.
Watts Bar Standard Practice 4.1 dated December 6, 1977 delineated the requirements for material receipt.
The four individuals who performed receipt inspections at MBN Power Stores between February 1977 and December 1977 all had at least four years of experience working in TVA Power Stores before coming to MBN Power Stores.
Training and certification records (TVA Form 1453) vere found for Power Stores personnel dating back to February 21,
- 1978, QA provided training and performed certification.
There was no formal training program for engineering personnel who provided technical assistance for receipt inspections.
Some informal training was provided.
The engineering units provided technical assistance
~onl in their field of engineering.
h review of receiving reports indicated that "Over, Short, or Defective Reports,"
(OS or D) were written for material that did not meet the requirements of the contracts.
The eng,ineering units still provide assistance for receipt inspections when requested.
An interview with a Power Stores Materials Officer revealed that in 1976-1977 (before the establishment of a QA group onsite) section supervisors received Qh material they had ordered but that in that timeframe, very little QA material was received.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 31 OF 38 AI-5.2 replaced MB-4.1 "Receipt Inspection," section on May 25, 1982.
At this time Quality Control (QC) inspectors assumed responsibility for Receipt Inspection for QA Level I items, Level II substituted items and Level II items to which Part 21 applies and for ECN material to which Part 21 applies and which is shipped from the vendor to Nuclear Power.
MBN Power Stores clerks and Quality Control inspectors receive training and certification before performing receipt inspections.
Training and certification records are in the permanent records system.
This was found to be a Class C issue for WBN Construction and a
Class A for MBN Nuclear Power.
4.3 Persons Authorized to A rove Nuclear Power Stores Re uisition-575 4.3.1 Generic Not applicable.
4.3.2 Site-Specific - MBN QTC provided information that concern IN-85-412-001 applied to Nuclear Power only and is an on-going problem that currently exists.
MBN AI-5.4, "Material Issue,
- Transfer, and Traceability,"
was reviewed.
The current revision (Revision 12), delineated the requirements and responsibilities of plant personnel in the issuance of materials.
AI-5.4 did not establish a limit for the number of people who may be authorized to sign Power Stores Requisition-575 (a form used for requisitioning material from controlled storage).
I IR2 I
An interview with the assistant supervisor of Nuclear Power Stores revealed that Power Stores personnel who issue material received formal training on the use of Power Stores Requisition-575 and were certified by the QA group.
There were ten people listed as issue clerks, Three of the ten were trainees and worked with a certified clerk when issuing material.
A review oi the training records showed the other seven issue clerks to be certified, The supervisors of five units (Mechanical Maintenance, Electrical Maintenance, Instrument Maintenance, Modifications and Operations) whose employees comprised a majority of the 307 persons authorized to approve Power Stores Requisition-575, were interviewed, No formal training on the use of Power Stores Requisition-575 existed for those sections.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NJMBER:
2 PAGE 32 OF 38 Twelve incomplete Power Stores Requisition-575N were provided by the Power Stores personnel.
These 575s had been presented to the issuing clerks between March ll, 1986 and April 14, 1986.
Six of the 575s were presented on five different days
{an estimated 55-60, 575s are received daily by the Power Stores).
Eleven of the 12, 575s were for general plant use.
Approximately 30 completed 575s were reviewed.
One 575 (Power Stores Requisition Number 628606760) listed the Qh Level as NR (Not Required) but the material was actually QA Level III.
The issuing clerk detected and corrected the error before issuing the material. It appeared that information had been added to Power Stores Requisition
. 628606784 which indicated that the Nuclear Power Stores clerks were insuring that the 575s were completed.
The authorizing document (MR-499566, MBPE48 45-1) used for material traceability was on both 575s.
Twenty-two Power Stores Purchase Requisition 575H were checked on April 28, 1986.
Three of the 575s appeared to have been incomplete but were completed before issuing of'any
- material, and none of the three 575s were written for Qh material.
1 Interviews with Power Stores personnel who issue materials indicated that they had few occasions where Power Requisition-575s were signed by unauthorized personnel and was not.considered a problem.
Material was not issued for 575s signed by an unauthorized signature.
Fifteen Power Stores storage bins were checked for QA level identification.
Fourteen of the fifteen bins were labeled as to their Qh level and while the label from one bin was
- missing, the material in the unlabeled bin was marked with the contract number and date of the contract which maintained traceability.
Interviews with QA personnel did not provide any specific information on the use of the wrong, Qh level material, but did reference some Qh activity surveys.
These surveys (16PC(e)-84-1, NN AS-84-101, MBN AS-84-83 and MBN AS-84-168) dealt with issue of materials, traceability, and preparation of TVA 575D.
The surveys listed problems found which included finding some incomplete 575s.
h corrective action report and deficiency reports were written which addr'essed the problems.
For Qh Levels I and II material, QC Field Inspectors verify that the material'as purchased from Nuclear Power Stores and that it'matches the Power Stores Purchase Requisition-575.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 33 OF 38 Conclusions No formal training on the use of Power Stores Requisition-575 is required for people authorized to approve Power Stores Requisition-575.
WBN Power, AI-5.4, "Material Issue,
- Transfer, and Traceability," contains the information needed to complete the Power Stores Requisition-575.
'The Power stores Issue Clerks are trained and certified on the use of Power Stores Requisition.
Issue Clerks verify that the material is issued to the same QA level that it was purchased to.
AI-5.4 delineates the requirements and responsibilities for using Power Stores Requisition-575.
Formal training, on the use of Power Stores Requisition is required for Power Stores
. personnel who issue material.
Issue personnel are trained and certified to issue Qh Material to the QA level of the material as identified by contract number or the TVA Item Identification Code (TIIC) number and to assure that the correct QA level is on the Power Stores Purchase Requisition.
For Qh Levels I and II material, QC Field Inspectors verify that the material was obtained from the Power Stores and that" the material is as stated on the Power Stores Requisition-575.
There is not an established limit on the number of people who may be authorized to approve Power Stores Requisition-575.
The -plant manager authorizes personnel on TVA Form 1733 to approve Power Stores Requisition-575.
The number of personnel authorized to approve Power Stores Requisition-575 should not adversely affect quality as long as established procedures are followed.
This was found to be a Class h issue.
5.0 COLLECTIVE SIGNIFICANCE 5.1 Si nificance of each Issue 5.1.1 Construction Warehouse Personnel/Clerks The significance of this issue is that the CI apparently had a lack of understanding of the responsibilities of the Warehouse clerks.
Their responsibilities include inventory, receiving and issuing material but excludes inspection processes required by the respective procedures, codes and standards.
These inspections are performed by personnel in other organizations,
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 34 OF 38 The issues addressed by the ERT/NSRS Reports and their respective recommendations of actions/dispositions were responded to by MBN (DNC) via an action item list containing the twelve (12) actions required for resolution.
These
- actions, including training of WBN Construction warehouse
- clerks, are being tracked as e side issue via CATD 40800-QBN-01.
Receipt Inspections Training records reviewed f'rom the MBN Construction QA vault revealed that MBN Construction Receipt Inspectors were trained as required by DEC-QCP-l.ll as early as March 1975.
Before 1975 the MBN Construction Eng,ineering, Units provided informal training for members of their individual units.
Personnel certification was required by upper-tier document but the program did not address certification before March 24, 1975.
Training was required and performed before 1974 and did not change when the certification program was established.
Permanent documentation does not exist for this training A review of'he MBN Construction Receipt Inspection Program revealed that nonconformances were being identif'ied during, receiving inspection and that these nonconformances were documented for corrective action.
No MBN site procedures for Power Stores Material Receipt Inspection was found for the period from February 1977 to December 1977.
However, records show that items were being nonconformed during that time and that no Quality Assurance Level I items were received during that time.
A Quality Control Program was initiated in 1982 to centralize activities and present a uniform structure for control of
- material, equipment, and activities.
Under the new program, WBN Construction warehouse receipt inspection was separated from the Engineering, Unit and Nuclear Power Quality Control Inspectors assumed the responsibility for appropriate receipt inspection at MBN Power Stores.
Also see conclusions in section 4.1.2.
Persons Authorized to Approve Power Stores Requisitions-575 I
IR2 I
Training is not required for personnel authorized to approve Power Store Requisition-575.
Training is required for Power Stores Issue Clerks who are responsible for verifying the material QA level is in compliance with the purchase documents.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NlBNER:
40800 REVISION NUNBER:
2 PAGE 35 OF 38 The Office of Power Quality Assurance Procedure 7.1, Revision 0, dated July 7, 1976 stated that personnel performing receipt inspections shall receive QA training and certification.
Receiving records indicated that some receipt inspections were performed as early as April 12, 1977.
The earliest QA records found for training and certification of WBN Power Stores receipt inspectors were dated February 21, 1978.
Also see conclusions in section 4.2.2.1.
IR2 I
5.2 Si nificance of the Subcate or 5,2.1 Site-Specific-WBN The training program at WBN for warehouse clerks and receipt inspectors was developed slowly due primarily to site procedures for training not being devised and implemented in a timely manner by the responsible organizations.
The program for receipt inspections was improved in 1982 by the initiation of a Quality Control Program designed to centralize the Receipt Inspection Activities.
6.0 CAUSES 6.1 Warehouse Personnel/Clerks The concerned individuals (CI)s misinterpreted the position description of warehouse personnel.
The CIs perception of "Receiving" >> of materials and "Receipt Inspection" >>>> appeared to be one and the same
~
There were some cases of inattention to detail rather than lack of training of warehouse personnel.
- However, WBN Construction is enhancing their training program for warehouse
'lerks and correcting isolated storage problems and this is being tracked as a side issue on CATD 40800-WBN-01 Revision 0 for closure verification.
<<Receiving is a function of inventory control.
<<<<Receipt inspection is a function of item identification and verification of purchasing requirements.
6.2 Recei t Ins ections No problems affecting quality were found in this evaluation of the WBN Receipt Inspection training program, 6.3 Persons Authorized to A rove Nuclear Power Stores Re uisition-575 No requirements for training of people authorized to approve Power Stores Requisition-575 were found.
IR2 s
I I
IR2 I
I I
I l
I IR2 I
TVh EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PhGE 36 OF 38
- 7. 0 CORRECTIVE hCTIONS 7.1 hlread taken or lanned 7.1.1 Generic Not applicable.
7.3..2 Si te-Speci fic MBN h Quality Control Program was initiated in 1982 to centralize activities and present a uniform structure for control of
- material, equipment and activities.
Under the new program VBN construction and warehouse receipt inspection was separated from the engineering units and Nuclear Power Quality Control Inspectors assumed the responsibility for appropriate receipt inspections at MBN Power Stores.
WBN Construction submitted corrective actions for IN-85-369-001 in a response to Nuclear Safety Review Staff Recommendations Q-IN-85-369-001-01, -02, and -03.
Q-IN-85-369-001-01 has been verified complete by this evaluation.
Q-IN-85-369-001-02 was addressed in the program enhancements listed in the construction response to Q-ZN-85-369-001-03.
CATD 40800-MBN-01 was issued to track the completion of the open items in Q-IN-85-369-001-02 and -03.
The corrective action for CATD 40800-WBN-Ol as proposed by MBN DNC and concurred with the ECTG is as follows.
The items below correspond to items found on pages 8 and 9
of Attachment D.
1.
Two SOPs were developed to answer this concern (SOP-PMS-07 and SOP-PMS-08) and were approved for use on September 16, 1986.
Training for the warehouse employees was completed on November 5, 1986.
2.
The initial training on all material clerks (storekeepers) is complete with the exception of one employee who is scheduled to complete. the training in January 1988.
This concern originally came about from the statements made that clerks were not properly trained.
As a final attempt to clear up this matter, a corrective action plan was initiated in a memo to Stephen M. Gillis dated November 21, 1986.
hdditional training to employees was begun and has progressed slowly because of the workload.
Copies are on file as each employee requested specific areas they need additional training in, and this program will continue until all employees have received that
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISl'ON NUMBER:
2 PAGE 37 OF 38 training.
No written exams can be required without approval by TVA Division of Personnel and union representatives, 4.
This item is complete and was done so on August 28, 1986.
A proposed sale in September 1986 was cancelled.
The material is scheduled to be sold in the next surplus sale which is scheduled for April 23, 1987. It was also decided that all heat numbers and TVA class and ASME code class will be validated for correctness against the heat log printout.
This change to include validation of "TVA class and ASME code classes" has been informally implemented since the validation program was started.
5.
This item is complete.
The original concern was complete on approximately December 22, 1986, when authorization was given to use the new computer program; however, full implementation is not anticipated until June 1987.
There is also a new program format now being considered which will broaden the information input that will be helpful to the engineering, units. If the format is adopted and the new program is implemented, it will extend the completion date by several months.
6.
The warehouse is continuing with the review of inventory material stored at the present time.
The material that was declared surplus by mechanical and civil engineering has been placed in a hold status until further notice, with the exception of the material that was requested by Bellefonte Nuclear Construction during a recent walkdown.
Bellefonte is in the process of preparing a formal transfer request for the material that was reserved by them during the walkdown.
Transfer of material to the Division of Fossil and Hydro and the CSB (Construction Services Branch) has been delayed until further evaluations can be made of the material that was surplused.
Anticipated completion is in June 1987.
4 7.
Overall consolidation of material is approximately 60 percent complete.
Completion in the main warehouse is in the final stage with several of the storage huts already completed.
At the present rate, the anticipated consolidation is to be complete in June 1987.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 38 OF 38 8.
This concern is being accomplished through the use of potential surplus listings that have to be made on a
quarterly basis in accordance with Construction Modification Interim Procedure-09 (CMIP-09), Revision 0.
Identification and Disposition of Ezcess Materials.
10.
This item was reported as complete on the biweekly response dated June 23, 1986.
Random checks are conducted on all stainless pipe and tubing in storage to ensure that caps and plugs are in place as required and replaced where needed.
7.2 Corrective Action Re uired as Result of Evaluation 7.2.1 Generic Not applicable 7.2.2 Site-Specific MBN No additional corrective action requirements resulted from this evaluation.
8.0 ATTACHMENTS Attachment A Subcategory Summary Table (Computer Printout):
List of concerns by concern number indicating safety relationship and generic applicability Attachment B - List of concerns by Issue/Element Attachment C - ERT/NSRS Investigation Report on IN-85-369-001 Attachment D - lJBN Construction
Response
to IN-85-369-001
0 TVA ENPLOYEE CONCERNS SPECIAL f'ROGRAM REPORT NUNBER:
40800 REVISION NUMBER:
2 PAGE 1 OF 2
ATTACHHENi' LIST OF CONCERNS INDICATING SAFETY RELATIONSHIP AND GENFRIC APPLICABILITY CATEGORY:
NATERIAf CONTROL SUBCATEGORY:
40800 TRAINING CONCERN NUMBER CAT HI-85-077-N12 NC SUB PLT CAT LOC 408 WBN GENERIC APPL B
B S
M F L Q B
NNNN REPORT QTC/NSRS P
INVESTIGATION S REPORT R
NS CONCERN DESCRIPTION REFERENCE SECTION
/J CATEGORY MC SUBCATEGORY 408 NRC IDENTIFIED THE FOLLOWING CONCERN 1.2.2, 2.3.2, 3.1.2, FROM REVIEW OF THE QTC. FILE:
"RECEIPT 3.2.2, 4.2.2.2, 5.1.2 INSPECTION OF MATERIAL AND DOCUMEN-TATION FOR MHICH THEY HAD NOT BEEN TRAINED'ER REVIEW OF THE FILETS THIS APPEARS TO INVOLVE POWER STORES PERSONNEL DOING RECEIPT INSPECTION.
IN-85-145-001 NC T50115 QA 408 WBN 802 NNNN RFPORT IN-85-145-001 The entire concern was evaluated in this sub-category although shared with QA/QC subcategory.
QUALITY RECEIVING UNIT NOT ESTABLISHED 1.2.2, PRIOR TO THREE YEARS AGO.
CI QUES-4.2.2.
TIONS WHY DIDN'I MBNP HAVE h QUALITY RECEIVING UNIT PRIOR TO THREE YEARS AGO.
CONSTRUCTION DEPT.
CONCERN.
CI HAS NOT FURTHER INFORHATION.
NO FOLLOM UP REQUIRED.
3.1.2, 4.2.2.1, 2
IN-85-369-001 MC T50023 408 MBN NNNN REPORT IN-85-369-001 NS WAREHOUSE CLERKS ARE UNTRAINED AND 1.2.1, 2.3.1, 2.5, 2.6, OFTEN MIX SAFETY AND NON-SAFETY 3.1.1, 3.2.1, 4.1.2, HATERIALSa 5.1.1, 7.2.2 IN-85-412-001 NC 408 MBN N N N Y T50013 REPORT 200-300 PEOPLE ARE AUTHORIZED TO SIGN 1.2.3, (POWER STORE REQUISITION -575),
FOR 3.2.3, HATERIAL AT THE MAREHOUSE, BUT MOST OF THEM DON'T KNOM EITHER HOM TO FILL OUT THE REQUISITION OR MHETHER THEY HAVE THE CORRECT MATERIAL OR NOT.
THIS COULD RESULT IN THE WRONG TYPE OF QUALITY LEVEL MATERIAL BEING INSTALLED IN THE PLANT.
TOO NANY PEOPLE NOM AUTHORIZED TO SIGN FOR HATERIALo 2.3.3s 3.1.3o 4.3.2, 5.1.3
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
40800 REVISION NUMBER:
2 PAGE 2 OF 2
ATTACHMENT h
=
LIST OF CONCERNS INDICATING SAFETY RELATIONSHIP AND GENERIC APPLICABILITY CATEGORY:
MATFRIAL CONTROL SUBCATEGORY:
40800 TRAINING CONCERN NUMBER SUB CAT CAT GENERIC APPL PLT
'B B S W
LOC F L Q B
QTC/NSRS P
INVESTIGATION S REPORT R
CONCERN DESCRIPTION REFERENCE SECTION //
CATEGORY MC SUBCATEGORY 408 IN-85-570-001 MC 408 T50054 WBN N N N N REPORT WAREHOUSE PERSONNEL LACK AN INDEPTH KNOWLEDGE OF MATERIALS SPECS 6 DIS-TRIBUTION OF ASME CODE MATERIALS.
TOTAL LACK OF TRAINING IN ADDITION TO PERSONNEL ATTITUDE.
1.2.1, 3.1.1, 3.2.1, 4.1.2, 5.1.1 IN-85-606-001 MC 408 WBN N N N Y T50057 REPORT RECEIVING INSPECTIONS WERE NOT PER-FORMED IN AN ADEQUATE MANNER, BY TRAINED, EXPERIENCED OR CERTIFIED PERSONNEL, DURING THE TIME PERIOD FROM THE BEGINNING OF WBNP CONSTRUC-TION UNTIL ESTABLISHMENT OF THE MAT-EIRAL SERVICES UNIT IN 1982.
ACTIVI-TIES PERFORMED PRIOR TO 1982 ALTHOUGH DESIGNATED AS "RECEIVING" CONSISTED OF ACCOUNTABILITYVERIFICATION ONLY.
DETAILS ARE KNOWN BY QTC.
1.2.2, 2.3.2, 3.1.2, 4.2.2.1, 5.1.2 IN-86-011-001 MC 408 T50189 QA 802 WBN N
N N Y REPORT This entire NS concern was evaluated in this subcategory although shared with QA/QC subcategory.
NO RECEIVING INSPECTION GROUP WAS IN EXISTENCE PRIOR TO APRIL 1982.
CI IS CONCERNED THAT "Q" MATERIALS RECEIVED PRIOR TO THIS TIME MAY HAVE NOT MET PURCHASE SPECIFICATIONS, AND MAY HAVE BEEN INSTALLED IN THE FIELD.
CI EX-PRESSED THAT NO DOCUMENTATION/HARDWARE VERIFICATION WAS PERFORMED OF RECEIVED MATERIAL.
CONSTRUCTION DFPT CONCERN.
UNITS 1 6 2.
CI HAS NO FURTHFR INFORMATION.
1.2.2, 3.1.2, 4,2.2.1
REPORT NUMBER:
40800 REVISION NUMEBER:
2 PAGE 1 OF l LIST OF CONCERNS BY ISSUE hTThCHMENT B Concern Nmnber HI-85-007-N12 IN-85-143-001 IN-85-369-001 IN-85-412-001 IN-85-570-ODl IN-85-6D6-001 ZN-86-011-001 Receipt Inspections Q..2.2)
Receipt Inspections (1.2.2) warehouse Personnel/Clerks (1.2.1)
Persons Authorized to Approve Power Stores Requisition 575 (1.2. 3)
Warehouse Personnel/Clerk
{1.2.1)
Rereipt Inspections (1.2.2)
Receipt Inspections (1.2.2)
e iVAg (4rJrl iu>'<41"O'C'r I r
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TO:
t4. T. Cottie, Site Direc ore Va ts Bar L'uciear Fiant Cl Cr
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FRO'1:
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S aEE, EBAS C<<K FEE < f 1986 1IUC
~M1 SAP ~X REGULA STAr" ZVKPZCcUiOII K'OR TREQlSH" c'J.
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Ei TO F RO'.lt DATE SUBJEC Guenter Vadevitt, pro<ac 5 net;er,
~at s Bar Nuc'ear Plant OC p
Denise pro<r~ panager, watts Bar E=ployee Conc rn Task Group watts Ba" Nuclear plant OHP Fi8 26 Pkn V/ZsasS BAR HGC 'LLIlT-EHPLOTE=" CONC".~l INVZSTLGaT Og REoOR~
TRU!SHAWL Trz itted herein is e ployee concez inventi ation report nu-ber Zq-85 369-001 and associated recc~nd tions dealing Mith e ployee concern n'
ber.;.'-88-'389-001.
Please respond to this repor" and recc=ndations by Ãarch 7, 1986.
Also, r. ke a report bility dete=inc ion and inc ude this a"d any applic ble corrective action i==le=cat cion date in you" respcnse.
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C fl Uncck c ns c-- v -c ca e'-e su-.pc.
<he c'1eg
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R=.ORT YU"o-i 406 RZ VIS ION NUMBER:
ATTACHMENT C PAGE 6 OF 12 T TNVF5
< iuhTTON nCPonT PACE 3
OF CONC"RN NQ'"I 85-369-001 cant'nued Duzfng the cau ae o= the 'nve"t'c ia a
common p=cc"ice.
e:<'a"ed a= tecmi fns=ecd c= cne expe='ence C'ne
< nee
(
t-sining proc?cm uca iden-i='ed p?'o cant-cl pe?acnne n, houeve?, i" uca dete=m ned that ng tuo newly caa.gned pe?
cnne'o 1380 ~a?
any type o="
mate?fcl ge Mete-' l C l--a '
'-ka ln"e-v'ued cu-'c the fnve - '
- < o !
ue?c cene ly 'knauledcecz e
a "out the p=esen-ato?age p?cc" ces employed c
the I<Ic?chouse
~
Hcueve?,
he mc )o? 'yc='he Cle=i<l exhibited
=
ve?y pcc= unce s-nd'ng c=
..e Ouc'ity Asau=cnce
=e.u'?ementa cs hev zelc" e
?e o '
s-a=age cnd hend' ng c= mc=e?'
< he e?ka e~hib'nly c
knculecge c= "OA/Csee" m =e?icl/items,
<.e.,
m
<e ee
~ L u<
eae>>
c<<he Pc f C
'e c>>~ >>
<a ae L<<ec e'a Qr s ec ic,
~
ci e
t e
<>>v C ce is c ly c.pl< 'e <<p eaa h
e
? etc '.<<.: nc cnd su=pc?t 'e.",
>>..e unce=
."." '.".= cc>> he C'?ke m'ed
~
~
mechcn cc' tem cnc ra-
--" e'
"='
c v':,
HVc'
=erne, etc
~
J L
~
uh'=.".
mcy claa be ac=e=y ?e'c-ed, "u= ncn-;...= C=de.
No
-c mcl t?c 'ing a=
M -e?'
Con=?"?k tc e
= ='
he'd coc" m ence '= cedu=es ucs iden- ' 'd.
The cnly u=
= en t?uc>><<
~ cn pe?-
~ ning a the uc=ehcuse cc"
~vs ca rc-p?esc= 'e the cc
< v < iea DI ~
~ >>e e bcc?
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0 ~
he
~ (4) 'ndf vi duc '
ue?e s
na=
c=n===e" c=
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nc
..e
..ve cc c.,
n>>>>
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pc>>c?cq
="ence u'h c='
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th~
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e
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~
&0 ~
Cle ka c=e "un"= inec c=
the CA The wclkdaun c=" the uc?
hcve rc= ciucya been cd although much inp?aved, ehouaea and the laycoun ye=dc can='-m aecc=c"'".-. o-ee=etv cnd nan-sc=ety equate in the p
=,
crd "he p"e er.t c=e still fnadequcte.
ec
"".c" mc=e'?'cia c
h s
R PO"T Nt:..SERc (0800 REVISION Nt&BER1 ATTACHMENT C PAGE 7
OF 12 ZN<c>TjGATTQW R
- OR pAG 9 0 6
~ CONC:-RN NO:
IN-65-369-Oul t)ETAZLS continued hco (se a<<hoe gg
~
o 1
ac un pili (
plan=-
The i eos seLec=ac ue=a zhen cield I)u-in@ this p ocean i uas no-ed ha" va'ves na=ked.
end >>saaec
<<h=<,a<<.
ue e
s-o-ad uith non-ASH=
ve1ves.
pepin<
ga>>e-'a1 uas (l ~ e.,
ASt!2 Coca -La=ca he=a piscina ues loans,'="'ed a
AST?t na>>>>e-isL).
Addi-ionally,'eve=>>l 'eos had rc iden=i=ace>>>>ion (e. a.,
C nce<<-=
c Recuce=s in Ys=d 1, I.c scion C') enc. sooe i-a...s ue=e no=
>>he p
c e
s-o sae loc>>='cns.
These
.'ndiv<duaL p=c"1aos a=a
-'e c=
a Lac1c c>>>>
='..can
c n==c'i: >>he ua='ehcuse.
S
< c<<<
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he Qa 1
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etio-ance c=
<<he unco..==
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cn I
~ coun ne~-
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r.= and -he " ncinee-i.-,.-,"
'de
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~ he e =uc ma-e='="=
ce a
e s e.==esen=
a
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== ZO
=he==:Lo 'nc e=ess.
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R""PORT t"i!SER1 4PQ(
R=-VISION l'U."fmR1 ATTACH KNT C PAGE 8
OF 12 Igg P 5'7jG ATI0 i~
R " P 0 RT 1 AC:- -
OF 6
QgC PPf NO'kl 6 369 00 1 DETA
~ I 5, cent'nued Xn a-v'eMs u
ePP
<<N 111C<<e ncmenc3.cture, egardless o=
he ucrehcuse Pe==cnnel revealed that Qe le e
ve
~e'l d the sa e y unc cn ~
Me
=e1 e
=ad Based C<<<<<<<<C 1
~
uncs
~
t~cn ad end n
caen lv
'd env1rcnn c'neer'ng the cancer
<<ed ci'is Znsdecua
'a ha unc<<n>>
layd vn and En nc..1e Lc c>>u a
de-
@~cad l~
t~a Va<<ehou e
en" ident' 'd an he DC la areas:
the =ac" the=
items ident =y'ng n'v'ng c=
~ s =aty ol ~ Le s
4>>>><<
~ ~ >>>>I
~
Q Q
gp Pily
~
D ='nc the
~ g <<A
~
1 s<<
~
o>>
~ >>r
~ ~ 4 a<<
4<<>> <<
I
~ ~
ha Marahcusa
>>ha =-nc Aa s
s ce
~are rc-a 's ba
~ ng v'c1 Pa
<<c ha 60 -
~
~
ght Q
A c
a s
u'1 1
~e1 cJe a 101'sa d1s "i4 ca 1e c
a
- "e~s s= eked
=== s" crace cad sc "ha" rack cr='"'nc cr cr=tas era 1-a
'nc
..e ncu>>
c s>><<>>'c.
~ c>> le I a...;
ln ha>>
hcva na (2)
Mere stacked
. upcn each c"har and e
=ar '
i- "srd '-'6 1;ss u ac
= su-had
~
2 ~
c p s
~
~
~
~ ~
have enc
>> M
~
~
~
>> <<C
~ 1 4 n 1 <<
aa
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c
~ s aa'ha 1---- ~ ~ C h-ve all c-ve s, n==er a
c'd nc=
C 11C
+ ~'C w
~ Ma>>
<
- > o 1
1
' c1-.'c ca= '
anc a".
a 1 as <<<<<<
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~e -
u"c-t"a L= k c= kncMledca a
<<hey a'ta tc c
C'r a i a
<<a+a g
W ~
The lack Cleric'r c
a
~
'cr to 1 SC.
~ aL~A
~ <<
'A cc
>>n A
>>r ~'>>>>
a>> ~ ~
REGIS lON NL~!SiR:
ATTACH~~~NT Q PAGE 9
OF 12 ZNyg TXGATEQH REPORT P =:
6 COVC:-RN NQ:
IN-85-36<-OOZ
" DETAIL:, ccncXnued The c
15clcln p ac ce Q
he~ j~g p =-
~
c end. ane T e n ig P
Qc<<<<a>>
The leclc 0 c
Qa j a g >g
~n p +ceca ee p>>
The
?he lack c= =c"sally L
@ed e..d c n-=cL'ed. p=cc dt. ea ra deac='he r>> 1
'4 The c"
e = ~ack c= acute-ence e <<he em=a='. 'shed
<<<< =Ln'nc p
@=ac 1 e
> ~
g
~ e c~
I /<<
I
>> C~<<1C C
C e
ane
~
J r>><<(go e>>y a>>
rc-..-
e= e<<y)
~
~
p>>
The
~ r
~ 4 <<<<>> <<r>>~ ~
>> \\<<<<>>\\<<
~ ~ <
1 erJ>>r<<et Ca~'e" a
ee c
Tta
~r 4 <<~
~
~
"QC C a<<-- -'-"
r>>
<<<<e I
~
<<<<lp
~
~ >> <<>> ~
'The lack c="
in e c<<'t >>
The r' r>> l<<r I
c k.
,sg/
F r Ill 3
8 g
/~rrr R=VT=<ED Bu:
/ / '(//8@'
RZPOR at.}5 R1 40e REVISIO>> NlDfdER:
ATIACH~LcNT C PACE 10 OE'2 zcnnen o 1 phoae 1
c=
Me=chouse Melkdovn Items end Dlsc=eoencies L'st
~ol1oMinc 'e!!:s we=e selec" ed -=on the ledge= bool enc ohse=red he ='e'd
~
c!f>>>>q 6-sch 40 p pe, cA 212,
=16 L N7 Ce
~f ~ ~
CC p'=e.
A Wcne ecc=cec Flen=e, C rZ!>>a L
1
~ ~
C f ~
c 1 Qc CQ Cc o'M 2s csg0 Hfdf(
ceeo C ~ ~
g 1 fr C
X r
A
~ <<!C ~ C
!aae>>
~ ~
c e>>a a
c'sc=e"en=.
~ ~a>>
Qf er>>a>>q 1/>>
~ ~ }>>
chal 6CC>>
1 1
C '
vc 'e
~-7v:ZCE'" E,
="=ed 'n r'n-s.= =y 2.
W C"7 Lo ">>
~ ~
e, r.'!
p-'p wr 'c 2!1 0
}!'
!<ed e-A 7;!
n
'. r~
chef'1
~ >>1<<f >>
f I >>>>
m=
r.CM Car f>>1 Mes A '
e 1 !a>>
~
~ <
4 ffff a
~ ~f
~
P'e e,,0 r
f g
~
f
~
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r Ur'--
C>>
a>>
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>> 1>>>><<1
~
\\
I
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~
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.C r
r C
C C
Q 1;
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fr
~
0 Ci e
Of >>f w !r<<a>>'
~
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Vr
~ >>
ff C
e rr
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0"c --e'- e"-'a 7.
The =cc=
c= -"u'ine D-=,
Ye co C>>l >>
~ <<>>a>>f A
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='nc cn
"-e s in unc"n==clled L.C.
LeycoMn e"e ident. =led e
PN/CA/04 R 5516=1, 10' 1C" X 1/:",
AcOC G=
HT 77H' Completely urc=n==c' ed 9.
Mcr.-cence cine c o'e - ate=ious typeef Vnc n t."cl led
>>>>>> r<<
REPORT NU.'.S=R
~
4OS REGIS IOll )lU)ISER I ATTACHMENT C PAGE 11 OF 12 REQU
=
)'.E QRTl B ILITY EVct 'JPlTI Qlm
'tic. I sketrh s
e =
p
~~l T\\yg gg~ues No (Ewi Car:~
I ~.)o II l Zdent ifiCation Df I.'
.. vol
~ (ID No, x f reoor tec)
~>GIIenclature,
~ioc41 ~ etc
)
iA iaa 1o tele QC sys er.,
IIIanuf. ~ S~),
document s pho os veC:
WaYehonse Hate 'a1 GoYIt=nl t.le=I.s
~ ~
4
~
%~hot e
c
~ t~ a e <..
s a
o o ts
%i~ s
~
peas+I
~
~ C, Ylepol a
' /
(Use I'
Vier>ta
~r' iee a
neC'eS Sary)
'This desinn o.
- a<
-.uc-'
n Ce. icie. cv re-...a 'Iec unc=.. e te=,
coulh have a, fe eC of c erat'c s D. the nuc'esr p-
- e. p'nt tile CiIPB eC 8
- rl c"ncu--e" anvin l
- f. cm the H'
- u. e) syst e..o) '.
- nager, Mat s Bzr E-pI watts Bar tluc'ear Plzr.
- r. -hers Lt-S5-"-6c<O].
- labeling, and storage o E materials identified in this rcport need to be corrected via a quality assurance document."
- Again, the "control" of t!le catewal. is aaintained by reauiring a f nal inspection at the point af installation.
- however, the=e is far.rat'n j SuCh as rp8 anc f t lngs that number oi years.
- pipe, and <<ittings, vere secre",zted outs ce locat.'ons that cortes=end to <<K house 1 cc 5 cn leve of. materia.,
- I".ese or v
- c. e c "e~o.
- nuts, and bolts, wh ch do noc bee-.'n inspectors mark are made with an inspector present ro ver. fy Che issue.
- he
- 4 C
- sceos, we are able m
- roved, p 'ace
- progress,
- SCP, and copies of trainizg ooapleticn forms.
- oventyer, atta t m.
- 1986, attac!ment III, item, and attac!naW VI.
- RCR, RCR, CRR, dudit, etu.)
- 870319, Joe Inger and Svein Vigander.
Response
>c "s a QA code valve in Feb l979. The valve ~as issued in Harsh 1979 to the steufittcrs. The=e is aot a c=ed't record for return to the mrchouse; therefore, it uould not have been 1 sted a the ledge= books. It r s be assn=cd that he c-a=- lat = returned the valve bu did aot ol ow a-orooriat procedu= s fo= c=ed-ting back to uarehouse can =ol Qh'e bookkeeping ace au t4b ty vas v>>o la<<acr the t a>> Sb>> ' y o<<C thC va LvC %as maintained, A c=edit doc=.ent (a;A 575) has bec>>v lr lg '4 Ctt ar aa~ tne Va 'VC C<<CCate ta an cd 'CCS v. ~ I<- -"'" s-pa'<<S<<-c .". P-0 piper " '." 0.-", F.: lct ~27"37c; ZRSOC de o C C 'V ~ << I nis p 'p e -z s =cc eivec doc -entat'on 's available 'Zhe=e vas '=pwpcr pa'nt s-vhich have be ".. rewved. ~ > -'>>c sr E 97". It -had the heat as QA Level I matc c ~ c.c tea lltngs on the pape Rc s= c>>>>s c: C--'- c 4 ~ s<<c 5 <<c O>> ~ ~ <<v ~ <<S <<ger>>r t e potent a 'a<<c C'<<<< gs ab c' O CL4 C>>v a r has a p as- = end r ~ < v4 C << ~ s <<1 v<<'C sc=c ~ster c <<4 4 ~ cv C l ~ che=ked f=: C 0 L cvc.- o aches s rr ~ 4 n C ~ g ) O L cc un vnr d<<v 5o>> o'>> 1 v<<v c4 an ~+>> g)'1 l C. I 1 alrrA C'v 1 Mrong loc"t'o:1 c oocsc ' rw g b'e " p'aced on t e oin beam: at 4 co<<<<ec ed C '11'1l ll<<<<v 4 ~ ~ ~ ea Ths1s
5. Respanse: ~ ) H ".?8?5?51; Wrong HT number, sho)) 'ORT NU~!E'ER l I<<0f REq) ZS ION N)!.!BEE ATTACHMENT D PAGE 3 OF 9 have 390 feet o. 5" x 1'5 l beam in feet is l!T Pr]3)S)5] and 150 Eeet i-ll; 0?70SQ?3. l:L Mere urable co f nd any mark ngs as ?S?5'.51. Each Mas marked correctly. 6. piping macer'a,'ard 13-6) yard lC"5; Or<<capped or ends split
Response
This is a continuous problem vhere var'ance in tempe acure cause the plascic end caps to pop ouc or split. Thepe ice=s are checked each month and replaced on che month?y house) e p'ng tour. To help prevent Eut re oc" =ences ve are in the process o= se" -.'".," these enc caps w ch cape. Th's Mi'1 be cocolered April 7 r 1986 ~ I ~ The raa= o" building D-6, yar-:. 1; Brace o" rao" rest'.".'g on p'ping mate a P.esocnse: A suooorc brace r sc ng on sc=e 1 laRs ~a>>i ~ <<) lp>> ~ i a rao= sect cn hac settled anc l:as s a'less p Lpe ~ Tnas '@as ca a e. T sea=..n urccncra ec 5:==', )0' 10" x, u ~ p o ~ ~'e'C avcc /<<) <<) ~ C P ~ <<r 4'4L<< area icen =ed as P:.1/QA/OI-G- <<) I I <<?<<') C>> p e e) Pias<<c se ) ~ ~ 'l 5>>>>>><<<<a>>e a uL e" e Can>>
C P--'-g S" c car Pa<>'..S r.he fa".
PC '<<>>
a Lr<>.ie
~ S
<<'L sse s os ne ru-be s r..., in ver'='ca= c".-h c..er
'= takes
-, ac in the Lareho se c" in the "e'd.
A" the pc='nc o= inscaac'or)
] ace numbers are rereri=ied
'"". c"=alienee ": a oual'r".
contra
'.-. pector.
" che ru=ber canna be
=
aC cr Op p
<<LC LOS <<
op 'C
"~
P-S
.. -c a
o'
'1 cop
~ ~ ~
~ >>>>
c ui>>>> '
e
~
L
-'a-cco" se bu- "as r."
beo- '"s--l'e"'s "'--"e"
~ ~
Lbe cave e
u c
c" su
~
a o
s LO og C L ~
~ p S
p S p<<p i<<
~
)>>
v
'a C
a \\S<<ai ~
l(
i >>
a c>>J i
~
p e
c Ac a
i<< 'l a<>
S>>i c
Pe
~ 'I C p ac>>ual l..>>>><<pl<> Oii ~
Pi
~
s c..e No<<.>> vr<<SC
~ Lng
Response
1 a<< tea use cable score! unde" the conc"ol o the uare!louse had r... >>i ~ Oiip>>i ~ ~ Ca>> e Sca ac>>>> s C>>>> ~ QC tape and a NCR.sag Xascenedmo each ree'. To this c=ble aould oc" ". only ui"L. the purpcse'u'age 2
R:PORT hU~!SER 4080G REVTS10l'p NU"!BER: 2 ATTACHMENT D PAGE 4 OF 9 intcn= o. an ird-'viduc to violate t.le qual:y ccc:rc'; ~va jd arv Eu care up ~ ipp p. t.". ' p-pe, all nonconforming reels have been moved ta a location approximately 100 yards away and will be cavcred wi=!l carps. This cable was previously surpluscd and sold and is awaiting shipping. ~ The cable refe..ed to as '"Engineering Storage" is outside the warehouse yard and.is tHe stag ng area fo. the crafts. These are the "working reels" for the 'electricians and used far. thei. various pulls.
An inspector est be p" sent at the begin"'ag af each pul ta ve='w the prcper cable is be'ng used clang wi h the apprapr'ate pu'1 require=ents. any cable of a nancan a. ng nature that a c~fcsuan nrght subst cute would be ca gh-at this t'-e. I ue lacked up the stag'ng area ~d issued only a strand af cable at a t=ne fcr a speci= c use t..at +auld nat stop the use at anothe= unspec'=ied loca o>> Sar this reason, the control of prape= use ~ r\\ Rust CC<<" at the Paant at aC <<a .S<<a X<<C>>r 1D. Tn add=t'ar. ta the move, a~ ass ear ta be The = pert szvs "hat =ate= al rn the 1ecger c=='s ca d nc e fcundr To check the =a,n'tuce o= t.. s ue se ected ca 'tarn cescr'ptr cns of the r-aerial and 'ts designated locat'cn. 'Pe then lz"= ta the designated loca'ons to see (1) i= the were the=e ~d (2) if ii was properly ident'd by t- ?ia k 'g cn ca ta ne p o i the desc pc <<n '@vs pa d c a'ar!:ed c" t e te=.Cse a e adtngs o Cf ".he '"-"." ite=s on the books, 35 -ere rot '" ae ~ ra p a I C I ~ Cf -"e 35 cn hebooks censor'at S r' aa a<<M c<<y le 1 a a<< r ~ pe ~~SS aa.g a<<- ir'e>> e a P=p. <<" ve n',.e S tha>> Cauld nv>> be a<< <<u" a cf the Sa' ~ e "ates al bv tags
Vfe fc ".."'o "rable'ide"tifving a"..v cf th at=ached tc the aster ai., mark ngs or ces containers or on the item theaelves. problem of identr ficat'on of stenc'led in ! e=- ""-"e"a o" '-a-r 1 ke c""'r s-ee' are stored outside and have been there a P a 3
~ 'I ~ VI~ 'I ~ I 1 ~ ~ V VI RZVISIOY NUilBER.. ATTACF~ t'T D PAGE 5 OF 9 e.coosrd tc thc elements for 8 to 10 years. Th:s vi1. be addressed in ou: overz 1 pl"n to reviev all mater zl znd to ke p <<hat c=n be cleaned up and used and surp1us the remaining for s=le. b. We have some icems stored in AS::! locations that have AS:.K mar!cings For ins "ance, a pie" e of macerial vas transferred in fhom the Hartsville jobsite. We requested AST'.! bu" .Harcsville only had AS!K. 4>en rece'ved, ve placed the material in the AST'! location since there vas its intendec use. An zudicor or investigator vi 1 see the AS:2 p"'nt stic! l mar!cings and assu= ve have errored in stot.ng the mzc.ial. To ccrrect this <<~ <<"'ll reviev all markings anc r 'ove the reference to AS:~ vhere <<m intenc che use the piece zs ASc '.!. Heat numbers v'e~in seamed into the r"ter al so the t=aceabi1'ty of the mzt r'al is macintzined. C ~ The reoort a'sc states thzt there vzs a "la k separat'cn (safety a=d nonsafety) pr or to 1 I t me=ra= There are or.ly four re=a.n ng peop vz ehc se that ver s ores c e ks z Wa ts Bzr l 79 ~ They s pp' ed the fol'ov'ng i"=c.ation race St znd S v z2e o z e z r o mz-c-z'0 IC le in the ~ hI ~ 4 c 1 OI ~ \\ h ev ~ c """a"<<-e" hs ~ 1 hh 1 C O 1 ~ c, r 1 1 I' I o I Se 1 coos 1 ~ 0 aI 0 ~ I cz 1 g ba 1C lw ~ Ite.x, suvh zs s=ee,
znd cor tract n<<-<<er vc c tie the r~tzriz ~ C c e - c"S Ve e 'c C O sta'less s vrzge ~ de $ I zg 1 zs c ~ 'ste c leve o= =.zt " z..he ledger czr" s a so ccrrespcnd ~ LCCShh ~ \\1 ~ 'I 1 1 1hh1CC ~ Q I 1 ~ ~eescv Iv ~ 41'1 ~ \\ ~ 11c ~ c 0 c c, c.' ~ c c cc 1 ~ a ~ c 1 Vc ---e-S --- r-r "i <<c-'-t <<.as c" cr cccec v .". c
=a
"..: c" ~ C Il ~ I ~ 1 C 0 1 ~, ~ 1 ~ Sne 1 <<c ~ VI~ 1 I v c ~ ac c c S c C I C 1 e P h c ~ ~ h leuc'nc i= mzt ~ 1 1 0 be Ic 1 ~ spec'cat'ors V<<S he~ he 1 d vcy C C e Ot gr VC ~ inspec='".". o ~teria to see '= the contr"ct re =et znd prover dcc-zntzt cr <<=s recezved Page 4
V W: >>VO REVrSZOW !I!l~!!!Z!LI 2 ATTACP ~ IT D PAGE 6 OF 9 and chec.ced by the responsible eng neer, the mvteriaL ucs stared in designated areas. led<<er car'5 far inventar-materral Mere checked ta ensure the =~ e" so being starcl! 1:-5 starec vith material having the sane speciiicst'an Q-I'5-369-001-02: . "Training of gatehouse Clerks" "Warehouse clerks should ke mained ia the appl'cable QA . requirements of their jobs 'This t=aining should be forwl, doc 'mented, and ccn=l ted under thee QA pro-r-m." The intent of the trai" n'p~gram est-blished ar material c=ntr=l clerks is to rotate persann
= ore phase af );zresa sing, s"ch -
race pt and issue, to othe= a=eas, such as &e ledge= of ce Qy doing this i/A'5 goal is to lesse the smpac ot attrit'oa by having all S3-4 persornel uho can eas'1y xuvc i=to anothe" job i= a sudde" vac-""y is created. 25 a cia k is t=aiaed im a pa " cula= a es nether he!she be a S"", -3,'" -4, he/she be"= 5 e igible to pe==a= in t..at ~ ~ v"'ence"t y-T' 1C h I to cu t..e stares
etc
c e=ks zs des 1'stad dated P<<arch 16) 1c71 ~ o r 4 <<4 vaS c 4<< (o'a av>>ache ) t c'c Cc e 2 O e '5>>e e (5 5 c Rs <<e ks oa e ao~ C Ne'--e-c= t'"e "-"g-==5 ere 'ntended t= tz'..e the p'a=e t z>>ino J.<< the a>>crv>>or~re auz ', c nt ol p II c" the QTC investigat a", ou= react s sham t..at each o= cle=ks aenticned im h's ~pert hac been trat..ec i-.. t..e stcrare and ho seke -'-." ~"J t."e "=ocedure cf -oce'vi"". pracecu=es a" "-.e he 1:i=ess'-..g c= ece a bv the insp cr".an "5= "".. an tne'r canc
== nce cn storage ere ass' so aes "".e=".:era ea a p e a c s-e II ~ II 4 ~ ~ race=ore c=
~ ~ 4 ct>> m ~ ~ 5 ~ C has be " --=- =e 4 4 '4/5 r <<<<r <<1 ~ <<r t I ako Lfsues ~ at r t>> <>er t ac 4 << or v beta= o ~ >> ~ ~ ~ v>> oc t >> I 'v t or 4 <<4 4 )'s 5 ~ 11 ~ or te I I vv a t ~ th's mill be autn c unaer the re" e=-"'r- -h s c"ace= Me have >> ~ r ns VV c Ct>> V ~ ~ ' CI) 4 ~ ~ tt ot ~ t lt ~ tao <<5 ~ 4 o J <>otb e c>>t ~ <<0 ~ ~ t 1 To ensure an uncersvnding or the issue o-pe=anent ma e" a, I vial outline the process. This be"ins crith he cra=t evpediter b-'ngin= a "rc"er'y pre"ared and a:".ar'-ed ~i'-' 'a" "e aarehc =e led<<or office. From the aescr pt'on given on the 5I5) the leag " o ice c erk locates the storage locat'on of the act rial and notes i on the Pag 5 ~ >> ~
~ Pg SVAP ~iL>> Sa'EVI SZOh NUHBER: ATTACH?Ka! D PAGE 7 OF 9 575 so the issue clark will know whet co go <<o ge. CLe mater.'cl fter thts xs cone,
A. 4 counter clerk, who in turn w:'.'ive the 575 to the issue c'.Crk fo' thee day. All issues made outside af the main warehouse "re 'always zcccmpzn.ed by an issue elec!c, and issues within the main warehouse are gsthe Qd by a warehouseman and taken Co Che issue counCer clerk Co be checked before issuing. All issues involving steel,
In the case of steel, each pie" e ~s be die s ammed w'th the hea" nu~er and val'dated by an inspec"" s d e sea=.. be=ore '- ccn be issued to the era "t. Heat numbers are ver>> 5 ed by the use o. the heat code log f'le.- I" heac numbers are nat 1'seed, the inspector ar. issue clerk wild, cake the contract numer ~om the ice= to be issued arc recurn Co Che ~-rehouse to pull Che f'le c".. Che cc"tract ard ver>> fy th-c i is a gaod heat nur>>ber and proper cioc..encacion is on fi' be fore ~king the issue. ~ ~ rw s anc bales e"-"- c e k co c> heat r: mer SS" Pl ~ e>> p>> ma ' C 4 ~ ~ >> Ppp 4 ~ 1 ss wa'<<4 4>> I>> ~ s c.e PP ~ >>4 1 ~ I e ~>> 4 ~ ~ s e >>e 4 ~ >>o ~ ~ go.P va 'accca 5 z ~ in pec""" "".'or to Va ys n Caae ppp c -c44b>> y c.. o
'ssue c erk 's ce ai".e a.. 'ns"ec-cr an" 'ss c "'c -re bc' e, p'pe ='= ngs, rucs a" d bolts (with hear, s..ow the heac n~e s was 'ssue so hx e =since'ne" after it has left w"reho se s""rz"e. re ocnsib e ~-- c"c..=en='n= -'".e hez= ".. =-er! s) cn to the era==. ~ ~ e.." v>> p ~ a ~ ~ 4>> ~ ~ a<<'>> S ~ 4 4' ~ Wa S C
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"Adequacy of Issued Hatcrial" "Since Lrazehouse clerks ue e not prope )y trained and mace ials vere found m'slabled and mislocated, an evaluation of the adequacy of DLaterial issued needs to be ~e and dDCumentesd under &e PA prOgrar."
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RZVlSZOh h'U."!BEE: 2 ATTACK~'.lT D PAGE 9 OF 9 Din~ nec. 1L 'll L sc uo to iden fy areas ard schlvu lc the ". cle=n up of discase d m-terial. This coolies to scrap areas anc l=y dole areas both insicc and cutside the varehouse yar A schedule for this effort vi'l be put togethc by AP'r 141 1966. Mates Bar site vill request the Kro.".ville s afis to do an analysis of compu er'='ng ou" ledge" system and plac'ng it on 'ne to avoid inherenc lag time for updating. II This reouest vi be m-dc by l!=rch 2', 1986. 6. TI c va chc1'se an>> O C al 1 S ~ VC>> ~ >>I ior prcpe= marki A.'= ssues v d o $1'-- c"nt=ol 1 11 se" a sc" edu Durin" th's r v ev, AS:.= 'atcria ngs ard valiaatcd ~ Du= ng the inte b zcco="a" 'cd cr chec!ted a" the g I C f>> tke $ el ~ 'I e>>J 1 bc c'"c"'e" C C$ CPVPD an C ~ A sta=t cate icr each oi ..ese has not be ".. se" bu" v>> 1 be no ~ 'L>> 'LID>>4 44 1 C I ~ a ~ C 1 ~ later I ~ cvera ~ ~ 4 4 4 n.e 4>>' ~I ~ ~ ~ ~ s . ~ "1 ~ V 4$1 L, ~ '. 1'C ~ 1 v v ~ ~ 1>> 4 ~ =adc he usc sc"resatcc. ~ ~ c D 4 DD>>$ ~ 4 C\\ Ic C T ~ s v 'c ..v - v-4 ya The above. V C a cas v bc Dc c an" scla Areas 196". e 4 4, C4g 4 4 ~ ~ 1 I c ='y 1 t.V ~ 4>> 4 4 t ~cse vt bc sc " c D ~ I ~ C 4 ~ 4 4 ~ c ~ 4 ~ Al 1 c C ~ ~ 4>> JD 4 $, usc C. C 4 4 $ 44 4 ~ v C is r>>p c ~ J Tn's vi 'e cc.== e c ~ >>Z ~ ~ C>>1 1 ~ .C A rev'sed orjanicat 0 ~ $ ra 4e ra>> ~ $ 4>> ~ fV cnsu$ c rcspons It a'so escablishe tra'n'ng
~, ~ ' lA>>a>>$ 4 I Toe "-"~os 1 iD"s dut s in tl e varenouse to =: various 1-r house operat cns re c ear. a position to reviev varehouse -"'ties, proceou== reau'=ents, ard houseicc ping. Imp le=e".tamon is penc>>ng this re cv. 'P D>>$ o >>)
Pan .'a a!, O,','Ct o Rene. I:. -l';0"OO 1. ~ ~ 3, 5. 6 ~ ,L, l.'o I!arch 12. 1966 con ainin~ ~ .se to emslo 'ee concern nuaber If'-85-369-001: Items 1 2 ~, 5 G. 7 8, and 10 of I!SRS Recommendation 0-35-369-001-03 have not heen comnletec. These items are as indi ated on htta !:ment A. Immediate Corrective Action Rec>aire': 0 Yes Stop L'ori; Recomm.nded: D Yes >-'!o CATD lf0 I OBOO-I 8 !-01 Pev 0 0. IllI I'TIOi DATE 10-09-86 PESPOI'SIBLE ORGAI!IZA IOI: f!Bll - r.:.C PRO" LEE DE"C.",IPIIOl!: C OR P l.'OR Eeaao to ll. P. Dt'r'.i "o Pro."rnm Hanarer ECIG prom Guen et"l.'edeaa::"" pro 'eet a o.".aaer t'Di.'-OC dated 7. 8, 9. PREPARED BY: lehl>E ~i ~It.~ COilCURREWCE: CEG-H ~. <.E V APPPaOVAL: ECTG PROGPafll HGR.~{'i&&a:;-.= ~;r U. hTTACifYiEI!TS D/tTE: ~I-/0-aC ='- DATE: //// > CCPRECTIVE ACTIO!a 10. PROPOSED CORRECTIVE hCTIOII PLAI,'. fC Paula R r Q ~ ~Q ( L g ~ 87 ll. PROPOSED BY: DIRECTOR/hGR: 12. CO!!CURRCI'CE: CEG-II:, SRP: ECTG PPtOGRA'lI I'aGR: an 0 >/nCE'l Tea DATE: D/;TE: DATE: i9/aTE: D'TP'$ F7 rg, ran ~yaaet E ~ eg Cl OpEaOIa~ 13. pproved co;rective ccticns have been verified as sati factorily 248iiI SIGNATURE TITL;: IE LC ~ ~ ~
A stc'lda C cpe c ' 8 p. ceuu e 'lSv: ) on "!a e '01 c'c.i. epona!h! ~ie will b>> written. l'is will include detciled information on how t!!oy are to ccrry out thci responsibilities. This will be completed hy April 7. 1986. 2. The training program will be more formalized and written e"am dove)oped to measure training e ectivencs . 'This is dependent on cpproval by the Division of Personne) This vill be in place by liny 5, 1906. A special creLr of c"afts, engineering, and warehouse people will be setup to identify areas cnd scl!edule their c)eanup of'disccrded mctericl. This applies to scrap areas and lay down areas both inside and out ide the warehouse yard. A schedule for this effort will be put together by April 14, 1986. 3. Matts Bcr site will request the Knoxville staff" to do an analysis of computerizing our ledger system and placing it online to avoid i'nherent 1ag time for updating. This request will be made by Larch 24, 1986. 6. The warehouse and quality control will set a schedule for the revie!r of all inventcry. During th s review, ASl!E material will be checked for proper n!arkings end validcted. During the interim period, all ASl "- issues will be acccmpcnied or checked at the gate for compl'.ence. A stcrt date for each of these has not been set but vill be no later than liarch 24, 1986. 7. An nvercll consolidation schedule w 11 be dove'oped with the intent of placing all like materials together. This schedule vill be finalized by April 14, 1986 A. All nutorial will bo reviewed for uooahility. churn cvrrosion hus mudo the use of the material ouestionable, it wi11 be surpl sed cnd segregated. This w'll be incorporated in item 6, 10. Requirements for caps and plugs will be reviewed. 'Uhere reouired, the e will be ecured with tap to prevent them from falling out. This will be complete April 7, 1986,
CATG CAPP 1.0 REV. 0 ATTACHNE CATD NO. 40800-VBN-01 10. PROPOSED CORRECTIVE ACTION PLAN: Item 1. So SOPs were developed to answer this co@em (SOP-BS-0? and SOP-F%-OS) ard were approved for use on Sep r, 1 for RRp oyees His eanpleted on Novenber 5, 1986. (Attachmnt I is copies of SOP-RBCV,
Item 2. The initial trainirg on all nateriel clerks shopkeepers is axplete with the exception of one enployee who is scheduled to cxaplete the trainirg in Jaruary 1988. 'lhis coraern originally came about ~ the statenants e that c e mm not properly trained. As a-fina'theist to clear up this natter, a corrmtive action plan ms initiated in a menxy to Stephen M. Gillis dated
Additiaal training to enployees ms begun and has progressed slcwly because of the worklcad. Copies are cn fQe as each enployee requested specific areas they needed additional training in, ard this prcgram will oontirUe util all employees have mceived that trairdng. No written exams can be mquind without approval by Personnel and union representatives. Item!1. 'Ihis item is canplete and ms done'o on August 28, 1986. A prcposed sale in Septenber 19 ms carreUed. 'Ihe naterial is scheduled to be sold in the next surplus sale which is scheduled for Ap~ 23, 1987. (See attached response dated Septenbor 12,
(>Continued on attached s eet Item 5. Rls item is cccple".e. Ihe o~al concern ms completed on approxinately 1986, &en mt&rizaticn 4m given to use the new ac~uter prcgrnn. 'Ihe work to be not canplete. 'Ih anticipated conpleticn date is June 19 '!here is also a new program fornat nm beirg considered which willbroaden the infornaticn ~t that will be helps. to the e~~ ~ts. Ifthis format is adopted an". t!a Mw prqpam is iwlanented, it will extend the occpleticn date by several nnnths. (Ccntixued on attached sheet) Does the corrective action plan rely on or take credit for currently identified or previously oonpleted uork? yes Ro Zf yes list parent doounents ie.t.
Does the pr'oblem described constitute a condition adverse to quality (CAQ)? Yes No X If Yes CAQ No. Schedule for completion of corrective action (schedule date, if known, or milestone (e.g. BF1.1, etc.) See above response or anti ip ted completion dat< 0320V Prepa&'d by/Date /Xp~ roposed by/Date / I
CAm m. 00800-hSN&1 Pgp~ CORKCITVE ACKET PULK'. (Ccntimed) I~ 6. ihe mrdxuse is contiming with the review of inventory aaterial stored at the present time. 3m naterial that was declared surplus by mechanical and civil ergineerirg has been placed in a hold status until further notice, with the exception of the naterial that ms requested by Bellefmte Nuclear Ccastru ticn durizg mr mmnt mllcdown. Bellefcnte is in the prccess of pmparirg a formal transfer mquest for the material that ms reserved by them durirg the mlkdown. Transfer of material to the Mvisicn of Pcs'. ard~ md to CS8 has been delayed until further evatuaticns can be aade of the material that ms surplused. Anticipated ccapleticn is in June 1987. litem 7. Overall consolidation of materials is appraxhnately 60 percent cccplete. Ccmple'.icn in the nain ~9uum is in the final stage with several of the storage huts alnxdy ccrpleted. At the present rate, the anticipated consolidate.cn is to be ccnpleted in June 1987. Xten 8. 'this cxmem is beirut accceplished thrtugh the use of mr potential surplus listings that have to be made on a quarterly basis in acconh~ with QGP-09, Revision 0, Ide~Qcaticn and Rspositica ofBurns materials (see attachlnt ZV). Ztem 1D.~ iten ms repor ted as axplete on tur bivmkly response dated Ane 23, 1986. Randan ~ are abducted on all stainless pipe and tubing in garage to ensure that caps and plugs are M place as required and replaced where needed (see attachment V, item 10). <<I~ 0 (Contre"). A mpplmmt nemrandum to attachzmt VE, page 2, ~~ph 2, is be~ revised and will be reissued to add "... all heat ruxem aud T/A class anf ASS code ~g sashes will be validated fbr correctness against the heat lcg printcut. dPR 'Ihis cthe to in:lude validaZcn of "TVA class m}~ cede classes" has been inforrally i~lcm&swe the validation prcgan es su"N. Concurred,
(Correction -numbers-t'o-class-by SV as per phone instruction from Nancy Ladd) gV 8703 lol
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