ML20085A872
| ML20085A872 | |
| Person / Time | |
|---|---|
| Site: | Three Mile Island  |
| Issue date: | 09/11/1978 |
| From: | Roy D BABCOCK & WILCOX CO. |
| To: | Fahland F BABCOCK & WILCOX CO. |
| References | |
| TASK-*, TASK-GB GPU-0456, GPU-456, NUDOCS 8307070354 | |
| Download: ML20085A872 (18) | |
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p, f THE BABCOCK & WILC0x COMPAhf POWER GENERAil0N GROUP To l f F. R. Fahland, Product Development, R&D Section ;
.' Froe (Ext. 2375) s e s . 3.3
- 0. H. Roy, Manager, NPG0 Engiv_ering
' File Mo.
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Date su bj. September ll,1973 ; Availability Information F1cw j t The coments put together by Bob Burnley Harry Honig, and Larry Xing dealing l with the "Infomation cycle
- as related to availability problems in the field is "
. deserving of followup. I think yod and I have heard enough in the last two weeks
- to conclude that trere is a real problem associated with the accuracy Dick and' Kosiba e,
' conpleteness of the equipment failure information we are receiving. f.
is charged with the task of overseeing the Division-wide approach to resolution f of availability problems and I would appreciate your working with him to develop a more effective system for acquiring equipment failure information. This in l' no way absolves the responsible equipment engineer from the task of seeking this
" information for himself and for dealing with the problem using available data. '
We should proceed in parallel, however, to:
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a) Improve our information flow from the field, ' b) Elicit more e(fective responses to SPR's which arc submitted to equipment vendors,
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1 c) Euild a greater sense of availability concern among our service managers,
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d) Identify all arrangements.and agreerents with our vendors which , t could be used to enforce or encourage equipment upgrades (such as - l the fuel handling equi *pment upgrade i arketing agreement with l HFC). d\ my A %\. i
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DHRinw Attachment i l (U I cc: R. E. Kosiba - w/att. G. M. Olds - w/att. Delt. Exil. For ID HN - 1 Pff-ExMa-Ev D?$o'rY!n'g??c? C h 0N$DEY W 8307070354 780911 05000289 {hDRADOCKHOL 318E0 9 9.ial, i '~ E15 ,N Y S.T,_
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t I' h l AVAIIABII.ITY DtFROVDET ACTION iLj(( f I,
,. The FCD goal of 901 availability by 1980 af BGf supplied cc:vaercial nuclear l steam supply systaas and the casaitment tcuard achieving the above requires a clearly
- t. defined plan. E=phasis on lost capacity days attributed to valves resulted in the Engineering Department M2 nager directing that such an action plan be devised for valves. The AIAP presented here has been put together with the adled objective that
; it can be used for cost, if not all, situations that might cause or contribute to
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! lost capacity days. The two -aain objectives of this plan are:
I i 1. Drive down lost capacity days which results in improved availability.
- 2. Factor in the knowledge gained frca past and current experiences to eliminate future problems. '
Action which must be taken to make this plan work and be productive is shcun en the flow charts and is describcd in detail in the texi: for the individual porticas of this plan. T o major actions must occur to put the plan in place and =ake it work:
- 1. BGf ccumitment of'its resources to man and fund the plan.
- 2. 'tJtility cocmit:nent to BGf to support the plan with utility resources.
A /.esired information cycle is shown on AIAP Flow Diagras I. This diagra:n shows the basic elenents for a functional infonnacion cycle. ~1he importance of gathering, dissasinating and productively using intelligence cannot be over-enphasized. As shown, BGf is the focal point with a number of input points, both fras'oper'ating piantsand outside sources... Circled nunbers on this diagram are cross references for succeeding parts of this AI.W.
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. Flow D agran II portien of, the {riforrant[ogcle,hQspec' fic,'a,cpidh~itbis i
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to which the utilities and BGf =ust cennit for .a. succe:sful.progra: - . . . . . . . .. 2. g, l The BC,f Site Engineer desipated for each of the reporting units is on ihe critical. l . .. . ..... .. . .. . .. i- _ - -.. path of the Peliability aW1.M11ry Dmam. %is ,rwsition is the key to the success . l . .. . . J C0NRDENTIAL _,,7 , .- .. ,. , El5-'9D, i! 318.0 me,9 -9.91, f _ ...:w.
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' I or failure of this plan. Recomendations for Qualification required to adequately fill this position are:
I l Nst be mature individual; heavy in hardware experience; t mst have design and operating asckg ound; former field
, ' :, experience; exceptional ccmunicatioits skills and a demonstrated ability to gat along with a' broad cross section of peopic.
I FIcw Diagram III shows a more detailed breakdown fraa lines 1 and I on Flow I
! Diagram I. BGf Site Problem Report (SPR) Procedure NPG-0503-04 (Rev. 5) .is presently used to comunicate with the !iamo office. It has not been efficient or effective.
This procedure must be,1= proved (see attached check list). Other channels must also be initiated to transmit information. In addition to the SPR ite:a on this diagram other intelligence which must be gathered and reported are: (a) Current Maintenance Program How is the ulpnent stored, installed, maintained during storage and ing operation? Ibes this agree with maintenance recomendations? (b) Maintenance Planning Review plans made by Utility for: 1.. Schedule. ., .. . . . . . . .. .
- 2. Vendor Specialists ,
- 3. Adequate Spare Parts Inventory i 4. Detailed Operating mintenance History on Systects and Equip::ent l
(c) Operating Inforwtim Review systs and equipacnt operating modes with respect'to i pact---- - - on maintendrice"as well as Iung tem cifects ou specific Ataas.. I (d) Spare Parts - Replacmt Cocyc.nent.s - --- -- - - - - - - - - t . . .
! Review Spare Parts and Replaccment Cortponents. inv.cntory for adequacf 7 _ ..._ . . .. . . .. to suonort timely action for scheduled and. unscheduled =sintenance. .
j COMRDEMBE
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Flow Diagram III shows all inforcation flows thrcugh the*.% clear Service i D.partrent
- to the Operating Plant Task Engineer sal back to the operating plants Plus to backlog, Standard 'and downstresa contracts.
Diagram IV is an extension of Diagram III and shows a sumary of action ite::s I the Operating Plant Task Engineer cust take. Shawn below is a core detailed explana-tion of the OPII's actions:
- 1. He must assess the infc:=ttion .nl d:termine if a real probl=s. -
. exists and whether or not it is generic.
THE Ih7GURTION SUST BE EVALATED A D CLASSIFIED hTIII RESPECT
< 'IO HOW IT CAN ONRISIKE 10 tilGER AVAIIABILITY/ RELIABILITY.
- 2. He mus't investigate the reported information by enlisting the re-
- sources within and without afi.i to identify all factors influencing-the particular subject. Standard Pzocedurcs .is the A-1 m nual are mandatory for use of outside services unless waived by .
- management.
- 3. The CPIE will formlate I+ - -- .'2tions by develeping plans to resolve problaas and icplc= cat the resolutions. An example of the sequence of activities for a particular valve problas would be to: .
(a) Clarify Design Requirements (b) ' Rewrite Specification (c) Purchase design services and/or equipment (d) Purchase functional testing at design conditions (e) Make decision on resolutica based on results of a, through d_ i ! 4. The OPIE will presenc results and'recernendations to management for ' decision. At this point more work night be required dependant upon
. . , ~~~"'" - i managecent decisica; therefore, a recirc loop back to the TE is shes.n._
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- After management decision the cycle can be' continued'by 'tiansmitting l the plans, opgracea systa:s design, newfoetter equipnent offerings, etc.
j . to the utilities via eshMi<hi Cattract Services and/or :Nelear Services
. . mnagers- , _ . . , , . . _ m._.,, _ _._._ .... _ . ;
-l l t' ; . . m:tgred into. backlog, Standar.d and
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'Ihe sue input in 4via abovethe S-is f;Mi T.Es e3.- and C.ontract TEs.
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T. Tlle responsib 1 e Engtheering t.'siit*must*bb giien authurity to ske* * ' ! *.' things happen. It is suggested that management consider estab511shing _ - - , kN ~ x- .
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an operating budget which allocates manhours and a travel budget to permit full investigation of *any prob 1 cms which cause r cr.n cause significant lost capacity days.
! 2. Agreements between BCf and the utilities cust be established
. s which pennit ready access of personnel to the operating plants and utility personnel.
l
- 3. Policies should be established which allow the Task Engineer quick access via telephone or visits to BUf suppliers to resolve engineering problems. (Some type of standard inter-change agreencnt with suppliers might be desirable)
- 4. Any equipment that could cause or contribute to LCDs should undergo .
full functional testing including env'ironmental conditions before it is installed in a plant. [ j 5. B4W fully cannit all required. resources to support a viable Availability Improvenent Plan.
- 6. Obtain the necessary ccmitme$ts fran the Utilities to support the Plan with their resources.
. The above is a preliminary atte=pt to devise an AIAP. . Feedback will be incor-parated to improve the substance of the plan.
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_. . .- . - _ a. . . _ . - n __ 55/h~ d.., O En t. OECKI.IST l , SPR lf,j The following is a suggested checklist to ali the originator in gather- . ing the facts required to arrive at a meaningful resolution. It should i be noted that the items are not grouped according to any logic nor is l, cach itca applicalbe to every SPR. t
- 1. Is the proble:a related to:
6
. a. Inadequate performance
- b. Unacceptabic operation
- c. Wrong size or configuration
! d. Parts or materials cut of spec. .
- e. Not cceting pressure integrity
- f. Inst. or electrical cut of spec.
- g. Wrong identification or inadequate paperwork
- 2. When and Eho first identified the problem?
- 3. Ihd the sare probles occurred.on identical equipment?
- 4. 16 long has the equipent been in storage?-
- 5. Has the euqipment ever been dissassembled? By whe:a? t.ho checked tha i reassenbly? Was dissassembly and reassenbly done accordir.g to the Instruction llanual? -
- 6. hho was in charge of installaticn? Khat were his cecracnts?
- 7. Was equipent piped up and or wired up correctly? hhose epinion?
Ibcumented? Tested? - l
- 8. Were new spare parts installed as required when equipment was -
i reassembled?
- 9. Were torqueir.g requiremnts followed with respect to values and quence? . . . .
l * -.
- 10. Was equipment operated in a manner that satisfied the intended purpose? hhose opinion? h'as the purpose including -restrictions - -.
and limitation verified? Describe the operational malfunction' in , detail. Is this the first hand know1ulge, or was this relayed l, by others? Verbally or written? Give nancs. '.. . .. . . . . . . . . . . . _ _ _ . ._m.. . _ . . . . . . . _
- 11. Is water chemistry or suspended solids a factor? If so, give all
, Pertinent information. .. , . . . . . . .. . .. ,
I (O .. . ...
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- 12. hhat has the condition of the equipnent when it c=e cut of storage, i.e., still p:chaged as prepared by manufa'cturer.
t'as it stored in the position and environ =ent recomended? Was it ever dropped? I'ctsonnel contacted?
- 13. Identify all reference material by runber pertinent to the I probica.. B4t! drawings, specs., vendor drawings, instruction
- books, cperating instructions etc.
/
, 14. Describe in detail the damaged portien of the equipment. This applics to mating surfaces also. Sketches and photos are ex-trancly uscful. .
- 15. D: scribe the physical condition of the syste:n in which the cmponent is located prior to and during the malfunction with -
respect to: 'ficws, pressures, AP's, tc=peratures, vcitages, RPN, etc. .
~
Give the operating history of the cocpons it in question. Indicate 16. source of information.
- 17. During maintenance had any seals been broken that would nullify warrantee?
~ 18. Did the utility use the sexvices of the vendors fi'cId represent-
-stive? Is so; give name.
{ 19. tiere special tools / fixtures used where required?,
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E ( J-: - - - CONFIDENTIAL '
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tasCMa 4 m Cos C'# w m I , ADMINISTRATIVC MANUAL M POLICIES AND PROCEDURES m NPC-0503-04 (Rev 5) 5ECTICH suGJECT , TIII.D SERVICE SITE PP.0 LDi P.EPORT (SPR) COMPLETE REVIS!0M
- 1. APPLICABILITY , ,
ENCIAT.ERING DE.PARUG3T NUCLEAA SERVICE DEPARDE.NT PROJECT N/dlACC' JET DEPARTMENT QUALITY ASSURMCE DEPARTMINT , II. PUFIOSE To provide a unifors method for documenting proble.ns associated with B&W supplied systems, components or equipment af ter shipment from the supplier's (34W 'or other) shop, and to provide a timely resolution of site probicas on all af fected comtrsets. . III. ETTECTIVITY This procedure is applicable to all Site Problem Reports initiated af ter the issue date of this procedure. t IV. 'REFERP.NCES . h NPC 0403 Signatures on Engineering Documents NPC-0405 Change Inquiry / Authorization NPC-0412 Tornac - Technical Documents NPC-0503 Tield Change Authorization NPC-0504 Preparation and Processing of Site Instructions NPC-1202 Vendor Claims Procedure . HPC-1707 Reporting Significant Deficiencies, Substantial Safety Essards, and 36W Miscellaneous 2eportable Itess . V. FORMS PROCESSED (See Torus Section Manual) - BWNP-20141 - Problem Cross-Contract Accountability . , PDS -21091 - Site Problea Report VI. DETINITIONS_ ,
*- -~~. . -.. A.* Site Problete - An eq*aipment,, system or coerponent probles associated with - --
B&W supplied systems, components or equipment after shipment *from the supplier's plant (5&W plant or other supplier plant). It includes failure tot pass site receipt inspection or to meet acceptance criteria during pre-operational, start up, and/or periodic testing af ter unit acccptance. i It also includes problens arising-from Salance of Plant (BCP) design l requirements and cor puter/ test equipment sof tware prublems, problem oJt-side the 36W scope of supply that affect S&W equipment, and action which (, causes a forced, outage, a forced load reduction, or dovutime extcasion of an o,eratin. s ant. CONFIDENTIAL 3 . arv - - 's 4 s , .s,,,, , , , , i ., , , _ oP PACES P/EE 1' 2 J 4 : 516l 7l 4 i l l l l _L; as,selb. c.J. Al,A3,A4,A9 Page 1 f.'.rt . d 1_77
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P01.lCIES A;:0 PROCEDUR'S -
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/ VI. DEFINITIONS (cont'd)
- B. Site Problem Report Nu bers - Each SPR is sequentially numbered, starting with L (one) for each. contract. The full SPA number includes tr.e contract For fillag pur-number, serial (sequential) nucher and revision nuder. Ibe assign-
' . poses, a Docu=ent Identifier of 13 hJs been assigned to $PR's.
mest of SPR nusbers is the responsibility of the Nuc. lear Service Support Engineer (NS$E). If a resolutica of a Sitz C. _Problem VendorXaport clain - involved A cost clain assinst a vendor. costs chargeable to a vendor, a Cimia Report Work- . sheet shall be prepared in.accordance with NPG-1102-01. i be D. _7ield chance - A change to 34W supplied components or aqu pc.eut to implemented af ter shipment from the supplier's plant Shen any of the folla-ing conditions exiset ,
- 1. ne chansa affects 'the interface, function or interchangeability requirements of a couponent or piece of equipment as defined by 3&W requirements documents.
- 2. ne ch. age to 36u supplied equipment affects an interface between 3&W and customer supplied equipment.
- 3. The change revises the as shipped design requirements of the cca-Ponent or equipment.
E. Probicer cross-Contrace Acco.mtability - A form (SWP-20141) used to identify other contracts and/or th's Standard Product Line to which the problem say be applicable. F. Service Manacer - A Nuclear Service engineer who assumes the KSS Project , stanagur's rele as administrator of a contract once the contract has been declared coanercial and Project Man.ge=:nt tvrus cor. trol over to operating Plant Services Section of Nuclear Service. C. Pr sb1em Contact- Name of the perna to contact to obtain additicaal . Information concerning the problem. , VII. CINERAL .
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- - ~ . . . . 4.
The Site Problem Report shall be used to report all site problens knca '~ to NPCD and to document corrective action.- Corrective action shall be limited to restoring the equipment to its specified design er the indication of a document (e.g. TCA, Site Instruction, etc.) to resolve the problem.
- 3. All SPR's and markings on attachsents,co Spit's shall be prepared in blue ~
or black ink or by typewritten. , All markups shall be in accordance with TPG-4412-63. u d-1-77 Page 2 (Rev.5) *
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- 5. (coot'd)
If it becos. s necessary to make any changes to technical concla-t
,co:: sshall a.f5rer one or more approval signatures have been obtained, the origin----h-f t : e-indicate the changes as stated above, and previous approvers sW approve by signature and redating to indicate their approval _.
C. Ecylsions to SPR's shall be lialted to " treating the toitial prc=reable== and shall be accceptished by:
.1. Preparing a new SPR foca and increasing revistoa level by ny oce(~~), o
- 2. Mark.ing the revision on the existing s?1 and increasing th:==he servisica level up by one (1).
Za all cases, revisions shall regire the + at review and appt=:rrovan:s as the original SFA. D. Where time does not Fermit the orderly processing of the $PR^ Nef=rna tuple-mentatloa, the resoluties may be obtained via a Drx, h dtelecopie=1er cc= copy cxif B.x, c=r telephon
,provided the 5?1 is Lanediately processed vita the attac e telecopier oc , record of telephoce cctiversation.
VIII. FROCEDtat4
- A. For processiAg of SPF.'s, see Flouchart. Yrhthit A.
1 ' 3. For Review and Approval of 571's, see Appendix 1. -
'C. For Distribution of SP1's, see Appendix 2.
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- 3. W51E/Centrass TI/tatagratore (et destseee) provide reesistfes.
22tEt it se Centract it la asatsnad and it lavelwesent is re(61s.J. sAJ ltam and 21 (or dea 14ase) e re-tee. 6 Techalsal review of raselettee to assere all aspects et problem have. base resolvet.' Centract treject Naager: Approve'reseles.Less obtate cuatener appre 1 (it regelred). ., S. 6 Approve ta assure Camplettee tapert reflesta proper impleematasten et r.hlogies,.r, get .dntattees have been desusented.
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APPENDIX 2 DISTRIBUTIO;4 OF SITE PROB 1.Cf REPORTS
. FOR NSC COMPONENTS All Mfected Enrineering Unic Managers Manager Fuel QA-Mfected Project knager, NSC Fuel Team / Standard Flanc Manager Manager, Plant Integration All Affectsd Task Eagineers Records Center FOR NSS COMPONEh"rS ,
Mfected Froject Manager (s)/ Standard Flant maager Hamager Quality Assurance Zagineering All Miected Task Enginects Records Cocter Hamager, Plant Integration All Mfected Engineering Unic Managers h ,
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