ML20195D886
| ML20195D886 | |
| Person / Time | |
|---|---|
| Site: | Fort Saint Vrain  |
| Issue date: | 10/28/1988 |
| From: | Callan L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | Robert Williams PUBLIC SERVICE CO. OF COLORADO |
| References | |
| NUDOCS 8811070177 | |
| Download: ML20195D886 (28) | |
Text
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f In Reply Pefer To:
E 20 E Docket:
50-267 Public Service Company of Colorado ATTN: Robert O. Williams, Jr.
Vice President. Nuclear Operations 2420 W. 26th Avenue, Suite 15c Denver, Colorado 80211 Gentlemen:
This letter is to document the meeting held with you and members of your staff to discuss inspection findings relative to the refurbishment of the helium circulators. Attached is a copy of the slides presented and an attendance list.
As discussed with you during the meeting, we hwe gecific concerns regarding the adequacy of welding controls exercised by General Atomics International Services Corporation during(the refurbishment of Helium Circulator C-2101.
These concerns relate to:
- 1) repair of cracked strut welds using an improperly qualified welding procedure specification (WPS), and (2) repair of crack in the scroll using a WPS, which did not address all of the required ASME Section IX Code essential and nonessential variables.
It is our understanding that these concerns will be reviewed by you and that you will make a determination, prior to exceeding 35 percent power, of the potential effects on component operability.
Sincerely.
Onglnal Siyed By:
L. J. CALLAN L. J. Callan, Director Division of Reactor Projects
Attachment:
As stated cc:
Fort St. Vrain Nuclear Station Manager, Nuclear Production Division 16805 WCR 19)
Platteville, Colorado 80651 RIV:C:PSBOI 0:D TTWesterman;df LJCallan
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F Public Service Company of Colorado Fort St. Vrain Nuclear Station P. Tomlinson, Manager, Quality Assurance Division (saneaddress)
Colorado Radiation Control Program Director Colorado Public Utilities Commission bec to DMB (IE45) bec distrib. by RIV:
RRI R. D. Martin, RA SectionChief(DRP/B)
Project Engineer. DRP/B RPB-DRSS Lisa Shea, RM/ALF HIS System RSTS Operator K. Heitner, NRR Project Manager RIV File DRS DRP L_.
y ATTENDANCE LIST FOR PUBLIC SERVICE COMPANY MEETING OCTOBER 3, 1988 PSC H. L. Brey, Manager, Nuclear Licensing & Resources D. Goss, Nuclear Regulatory Affairs Manager C. H. Fuller, Manager, Nuclear Production P. F. Tonlinson, Manager. Quality Assessnent G. L. Redcond, Civil Program Manager R. O. Williams Jr., Vice President, Nuclear Operations
- 0. Warembourg, Manager, Nuclear Engineering NRC L. J. Callan, Director, Division of Reactor Projects J. L. Milhoan, Director Division of Reactor Safety R. E. Ireland, Technical Assistant T. F. Westerman, Chief. Project Section B I. Barnes, Chief. Material & Quality Programs L. E. Ellershaw, Reactor Inspector R. E. Farrell, Senior Resident inspector
- K. Heitner, Project Manager
- By conference call L
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-i MANAGEENT CONFERENCE OCTOBER 3, 1988 NRC REGION IV
- HELIUM CIRCULATOR OUTAGE SUWRY
- HF.LIUM CIRCULATOR PROJECT ASSESSENT
- HELIUM CIRCULATOR PROJECT, NRC REPORT 88-15
- Progrannatic Issues
- Specific Issues (Yiolations/ Deviations)
- General Issues
- HELIUM CIRCULAf0R FUTURE ACTION PLAN 4
- CORRECTIVE ACTION PROGRAM
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HELIUM CIRCULATOR PROJECT OUTAGE SupMARY' OVERALL OUTAGE ACCOMPLISHMENTS
- CIRCULATOR C-E101
- CIRCULATOR C-21i15
- PIPING ASSEA LY S/N-2001
- PIPING ASSEM0LY S/N-2002 i
- CIRCULATOR C-?101
- PIPING ASSEMBLY S/N-2004
- CIRCULATOR C-2104
- PIPING ASSEMBLY S/N 2003
- CIRCULATOR C-2103
- PIPING ASSEMBLY S/N 2000 r
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6 HELIUM CIRCULATOR PROJECT ASSESSMENT
- COMPLEX TECHNICAL / LOGISTICAL PROJECT PROGRAM MANAGEE NT TECHNIQUE
- SIGNIFICANT PLANNING / SCHEDULING EFFORTS
- Control of GA Activities
- Significant Technical Issues
- Complex Logistical Control
- Development of What-Ifs and Work Arounds
- NRC INTERFACE
- COMPLICATIONS OF QUALITY LEVELS
- CHANGE OF SCHEDULED ACTIVITIES
- OVERALL TIMELY COMPIET!0N i
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HELIUM CIRCULATOR PROJECT PROGRAMMTIC ISSUES
- OVERALL PROGRAM CONTROL
- AREAS REQUIRING ATTENTION
, SPECIFIC ISSUES (VIOLATICAS)
INSTALLATION WITriOUT APPROPRIATE AUTHORIZATION
- SPECIAL PROCESSES CONTROL
- Welding Procadure, GA
- Welding ProcWure, PSC
- NDE SPECIFIC ISSUES (DEVIATIONS)
- CHEMICAL / PHYSICAL TEST REPORTS
- NDE. STEAM INLET PIPING STUDS GENERT.L ISSUES
- PSC He CICC. REPORT AND COMtITMENTS
- GA VENDOR CONTROL 1
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i HELIUM CIRCULATOR PROJECT PROGRAMMATIC ISSUES i
- OVERALL PROGR/M CONTROL
- Special Processes Program, in General, Is An Acceptable Program
- Procurement / Receipt Inspection, in General, Is An Acceptal. ; Progrhm
- AREAS REQUIRING ATTENTION
- Management Focus /Otrection for Procedural Interpretations Involviig Uniquo Circumstances Procedural Evaluations / Revisions Hecessary To Avoid Unnecessary Restrictions, but Establish ar?, Maintain Adequate Barriers, Checks, and Balances Engineering Detail and Accuracy for Technical Reports Interpretations of Technical Report Content vs.
Project Specifications vs. NRC Commitments PSC Control of NSSS (GA) Work
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in HELIUM CIRCULATOR PROJECT SPECIFICISSUES(VIOLATIONS [
INSTALLATION WITHOUT APPROPRIATE AUTHORIZAT10N Receipt Insper'c an/ Hold Tag Receipt Inspe.ction/NCR Coatrol Installation
- Conditional Release System
- APM Q-8
- Criterion VIII,10 CFR 50, Appendix 8
- Work on Non-Confoming Component
- APM Q-15
- Criterion XV,10 CFR 50, Appandix B Innedtata Corrective Action
- Receipt Inspection /NCR Concerns Resolved Additional Planned Actions
- Evaluate / Revise Procedures
- Reinforce Managesent Focus and Dircction for Unique Circumstances
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HELIUM CIRCULATOR PROJECT SPECIFIC ISSUES (VIOLATIONS)
- SPECIAL PROCESSES CONTROL, WELDING
- Welding Procedure GA PQR vs. Welding Procedure
- Welding Procedure, PSC P-5 to P-5 Approved Procedure NCR for P-4 to P-4 Non-Coded Work Non-Pressure Retaining Parts Recoverable Position
- Welding Program, FSV APM Q-9 Program Audits /Overall Program Control
- Inmediate Corrective Action Ensure Appropriate Weld Procedure Approval
- Additional Planned Actions Evaluate / Revise Procedures l
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HELIUM CIRCULATOR PROJECT SPECIFIC ISSUES (VIOLATIONS)
SPECIAL PROCESSES CONTROL, NDE
- Fluorescent Mag Particle vs. Dye Penetrant
- Fluorescent Mag Particle Two Directional (QCIM-24; ASME SECT V)
- Immediate Corrective Action Dye Panetrant performed on load bearing section of all. studs
- Additio'nal Planned Actions Continue evaluation of QCIM-24 for adequacy Pending final evaluation, provide review of any QCIM-24 ch. o;3s for all PSC/NDE inspections.
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3, HELIUM CIRCULATOR PROJEE SPECIFIC ISSUES (DEVIATIONS)
- CHEMICAL / PHYSICAL TEST REPORTS, FASTENERS
- Spring Plunger Table III, Attachment 1, P-88019; Assumed designation as a fastener; Locking Device Tenninology; Report organization and clarity
- Procurement Detatis (0 pen Item)
Verified by inspection at GA
- Inlet Piping Studs Furnace Charts NDE Inlet Pipu Stud Shanks
- Action All Engineering personnel advised of Connitment deviations and Management philosophy via memo.
Begin a review of all P-88019 Connit-
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4 HELIUM CIRCULATOR PROJECT i
GENERAL ISSUES
- PSC REPORT, ATTACHMENT 1. P-88019 Interpretation by PSC Staff Tabular Infonnation NRC Interface /Cossnitments P-88019 Cossnitment Summary Total Cossaitments Made.......
58 Total Cossitments Complete As Designated by P-88019..... 41 Open Cossnitments Which Require Future Action........ 12 Cossnitments for Which PSC Defined Acceptable Alternatives.................
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- ACTIONS TAKEN/ PLANNED
- Memorandum to all Engineering personniti Complete review of P-88019
- Final letter to NRR summarizing acti tities t
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HELIUM CIRCULATOR PROJECT GENERAL ISSUES
- GA/ VENDOR CONTROL PSC Audit Program PSC Qualified Vendor Program Special Audits In-Progress Work Activities
- CONTRACT MANAGEMENT Centralized Contract Management Group Increased Emphasis, Project Control Specific Increased Emphasis by PSC on GA San Diego Acti'tities for Circulator Project l
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HELIUM CIRCULATOR PROJECT FUTURE ACTIONS
- UPDATE EXISTING C00MITENTS
- WOBBLE MONITORING
- WATER CHEMISTRY
- ASSESSENT OF SECONDARY COWONENTS INSPECTION PROGRAM CRITERIA
- IN-SERVICEINSPECTION(C-2105)
IN-SERVICE INSPECTION UPGRADE
- FINAL GA REPORT C-2101
- FINAL PSC REPORT JANUARY, 1989 i
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CORRECTIVE ACTION PROGRAM OVERVIEW
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CORRECTIVE ACTION INSTRUMENT i
AN APPROVED DOCUMENT WHICH IDENTIFIES 4
A DISCREPANT CONDITION AND INITIATES ACTION NECESSARY TO EVALUATE, AUTHORIZE, PERFORM AND RECORD CORRECTIVE ACTION IN A MANNER CONSISTENT WITH 10 CFR 50, APPENDIX 8. CRITERION XVI REQUIREMENTS.
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SUT MAY NOT PERFORM LICENSEE EVENT REPORT (LEM 10 CFR 21 REPORT NRC COMITENT LOG (CL)
CHANGE NOTICE PROCESS (CN, DCN, CWP, A DR)
PROCEDURE REVISIONS, ACTION REQUESTS (PDR. DCCF, & AR)
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Jf!STORICALPERSPECTIVE ON 10-1-86:
18 open CARS were more than 22 months old 19 open NCRs were more than 22 months old ON 10-1-88:
1 open CAR was more than 22 months old 29 open NCRs were more than 22 months old REASONS FOR CAR IMPROVEMENT:
- Corrective Action System (Q-16) has been reassessed and revised 1
- Increased management attention t
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RECEIPT INSPECTIONS part # discrepancies documentation problems shipping damage poor workmanship MAINTENANCE / MODIFICATION WORK failure to follow procedures Initiate Operability Review Engineering inadequate / unclear instructions NCR 5
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Disposition ared material failures i
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QA Approval material degradation field / documentation discrepancies AUDITS, QA DOCUNENT REVIEWS, WALKDOWNS field / documentation discrepancies procedural violations material use problems i
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7 CURRENT NCR STATUS TOTAL NCR's (since 1980)............. 3754 TOTAL OPEN NC R ' s..................... 20 5 AWAITING DISPOSITION /REDISPOSIT!DN....
35 (19 receiving)
AWAITING WORK / REWORK.................. 77 ( 6 receiving)
AWAITING DOCUMENT UPDATE.............. 93 (35 receiving)
TOTAL 205 (61 receiving)
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.o NCR ASSESSENT REASONS FOR LACK 0F NCR IMPROVEMENT:
- Failure to fonnally recognize NCRs are really part of Corrective Action System
- Failure to focus management attention
- Need for specific plant conditions ACTION TAKEN/ PLANNED:
- Focus management attention on NCRs along with CARS /QPRs and other Corrective Action System elements
- Reassess NCR process and revise as necessary to meet expectations
- Review of NCRs for oper2bility impact
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MANAGEM NT CONFERENCE ACTION PLAN SUMPRRY
' Reinforce Management Focus and Direction at SPT and Staff Meetings Concerning Pro-cedural Controls for Unique Circumstances
- Reevaluate / Revise Procedures to Avoid Unnecessary Restrictions, but yet Maintain Essential 10 CFR 50 Appendix B Control
- Continue Development of Centralized Contract Group and Increased Emphasis of Controlling /
Monitoring / Auditing GA Activities
- Bring the NCR Process Under Increased Management Attention by Establishing Reviews at SPT
- Update Commitments to NRC and Provide Data Outined in Helium Circ Project Future Plans
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9/6/88 OPEN CAR'S/MCATS/QDR'S ALL QPEN CAR'S/MCAR'S ALL OPEN QDR'S
> 188 DAYS 5.
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WD ED QA NLR WD ED QA PLR NPD ED QA ILR CAR's/QDR's issued this report period:
None CAR's/QDR's closed this repori period:
CAR-87-Ili (Block)
CAR-87-823 (Fuller)
CAR-88-181 (Craun)
QDR-87-184 (Clayton)
QER-87-187 (Borst)
QDR-87-189 (Eggebraten)
GDR-87-113 (Snyder)
QDR-87-118 (Reesy)
GDR-88-117 (Novachek)
Average age of open CAR's/NCAR's:
169 Average age of open QDR's:
288
_