ML20199K791
| ML20199K791 | |
| Person / Time | |
|---|---|
| Site: | Hatch  |
| Issue date: | 03/26/1986 |
| From: | Poertner K, Schnebli G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20199K763 | List: |
| References | |
| 50-321-86-08, 50-321-86-8, 50-366-86-08, 50-366-86-8, NUDOCS 8604100229 | |
| Download: ML20199K791 (7) | |
See also: IR 05000321/1986008
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UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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REGION ll
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101 MARIETTA STREET, N.W.
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ATLANTA, GEORGI A 30323
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Report Nos.: 50-321/86-08 and 50-366/86-08
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Licensee: Georgia Power Company
P. O. Box 4545
Atlanta, GA 30302
Docket Nos.: 50-321 and 50-366
License Nos.: DPR-5.7 and NPF-5 ',
Facility Name: Hatch 1 and 2
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Inspection Conducted: February 24 - March 3, 1986
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Inspectors:
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3/26 l86
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G. Seinebli
Date Signed
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K. Poertner
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Date Signed
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Approved by:
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F. Jape, Section Chief
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Date Signed
Engineering Branch
Division of Reactor Safety
SUMMARY
Scope:
This routine, unannounced inspection entailed 120 inspector-hours at the
site, in a review of maintenance programs and practices.
Results:
Two violations were identified - (1) Failure to implement maintenance
controls and document conditions adverse to quality - paragraph 5.a.
(2) Failure
to implement existing plant procedures properly - paragraphs 5.b. and 5.c.
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9604100229 860404
ADOCK 05000321
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REPORT DETAILS
1.
Persons Contacted
Licensee Employees
S. Barr, Maintenarce Supervisor
- S. Brunson, Reactor Systems Engineer
0. Fraser, Quality Assurance Audit Supervisor
- P. Fornel, Manager of Quality Assurance
R. Gatliff, Shift Supervisor
R. Glisson, Maintenance Engineering Supervisor
- C. Goodman, Regulatory Compliance Engineer
R. Houston, Quality Concerns Coordinator
R. Keck, Engineer Supervisor
T. King, Maintenance Foreman
D. McCusker, Superintendent of Quality Control
T. Metzler, Maintenance Engineer
- D. Morgan, Engineering Supervisor
- H. Nix, General Manager
- T. Powers, Manager of Engineering
- T. Seitz, Manager of Maintenance
- B. Thigpen, Quality Assurance Specialist
Other licensee employees contacted included outage craftsmen, engineers,
technicians, operators, mechanics, and office personnel.
NRC Resident Inspectors
- P. Holmes-Ray, Senior Resident Inspector
G. Nejfelt, Resident Inspector
- Attended exit interview
2.
Exit Interview
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The inspection scope and findings were summarized on March 3,1986, with
those persons indicated in paragraph 1 above. The inspectors described the
areas inspected and discussed in detail the inspection findings.
The
following new items were identified during this inspection:
Violation 321/86-08-01, Failure to implement maintenance controls and
document conditions adverse to quality - paragraph 5.a.
Violation 321/86-08-02, Failure to properly implement existing plant
procedures - paragraphs 5.b and 5.c.
Unresolved Item 321/86-08-03, Determine actual maintenance performed on
valve E11-F004B in 1981 - paragraph 5.d.
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Proprietary material was reviewed during the course of this inspection,
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however, the information is not contained in this report.
3.
Licensee Action on Previous Enforcement Matters
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This subject was not addressed in the inspection.
4.
Unresolved Items
An unresolved Item is a matter about which more information is required to
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determine whether it is acceptable or may involve a violation or deviation.
One new unresolved item identified during this inspection is discussed in
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paragraph 5.d.
5.
Review Of The Maintenance Program and Practices (62702)
This inspection was conducted to review the licensee's maintenance program
and maintenance practices in the area of valve repairs accomplished during
the current Unit 1 outa
An in depth review of valve maintenance in the
Residual Heat Removal (ge.RHR) System was performed.In this inspection, the
following documents were reviewed:
50AC-MNT-001-05, Revision 4,
Administrative Control Procedure
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Maintenance Program.
32GM.MEL-022-05, Revision 0, General Maintenance Procedure - Limitorque
Valve Operator Electrical Maintenance.
10AC-MGR04-0, Revision 0, Administrative Control Procedure - Deficiency
Control System.
40AC-ENG03-0, Revision 0, Administrative Control Procedure - Design
Control.
52CM-MME-011-OS, Revision 0, Corrective Maintenance Procedure - Gate
and Globe Valve Repair.
52-PM-MME-010-0, Revision 0, Preventive Maintenance Procedure - Safety
and Relief Valve Maintenance.
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50AC-MTL-002-05, Revision 1,
Administrative Control Procedure
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Identification and Control of Material and Equipment.
40AC-QCX-001-0, Revision 0, Administrative Control Procedure - Quality
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Control Inspection Program
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42EN-ENG-009-0, Revision 2, Engineering Procedure - Equivalent Deter-
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mination of Replacement Parts or Materials.
Maintenance Work order (MW0),1-85-7214 - Work Performed on Valve
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MW0, 1-85-7330 - Work Performed on Valve 1E11-F0178.
MWO, 1-85-7120 - Work Performed on Valve 1E11-F004A.
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MWO, 1-85-7216 - Work Performed on Valve 1E11-F0308.
MWO, 1-85-7019 - Work Performed on Valve 1E11-F007A.
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MW0, 1-85-7118 - Work Performed on Valve 1E11-F028A.
MWO, 1-85-7672 - Work Performed on Valve 1E11-F025A.
MW0, 1-85-7119 - Work Performed en Valve IE11-F0078.
MW0, 1-86-0615 - Work Performed on Valve IE11-F0248.
MWO, 1-85-7215 - Work Performed on Valve 1E11-F0288.
MWO, 1-85-7217 - Work Performed on Valve IE11-TRV.
MWO, 1-81-3328 - Work Performed on Valve IE11-0048.
MW0, 1-86-0472 - Additional Work Performed on Valves 1E11-F028A and
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MW0, 1-86-0987 - Additional Work Performed on Valves 1E11-F024A.
MWO, 1-86-1155 - Additional Work Performed on Valves 1E11-F004A.
In the review of the documents listed above, the following deficiencies were
noted:
a.
Maintenance Work Order (MWO) 1-85-7120 was initiated to repair valve
1E11-F004A, RHR torus suction valve.
During inspection of the
internals of the valve, it was determined that the valve wedge had to
be replaced and a replacement wedge was obtained from supply using
Purchase Order 7666.
During assembly of the valve wedge to the valve
stem, it was determined that the replacement wedge did not fit the
original stem supplied with the E11-F004A valve.
The valve stem had a
"T" head configuration whereas the wedge slot had an hourglass
configuration.
The maintenance supervisor, a Crane Valve employee,
directed his maintenance personnel to grind down the valve stem to make
the replacement wedge fi t .
The grindin'g of the valve stem was
accomplished on the verbal instructions of the maintenance supervisor
and was not documented in the work package reviewed by the inspectors.
Upon discovery by the licensee, efforts were made to obtain a replace-
ment stem with the hourglass design.
The licensee was unable to obtain
a replacement stem with the hourglass design due to outage limitations
and delivery constraints, so Crane Valve Services contacted ALOYC0 who
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contacted Walworth, the valve manufacturer, with a proposal for a
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temporary fix to utilize the existing stem until the next available
outage when a proper stem replacement could be made. Walworth provided
a sketch to modify the "T" head stem arrangement to approximate the
hourglass stem arrangement that per the Hatch drawings should have been
installed in the valve.
No attempt was made to determine why a "T"
head stem and wedge were originally installed in the valve, nor was a
design change request initiated to modify the existing stem.
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10 CFR 50 Appendix B Criterion XVI states:
Measures shall be estab-
lished to assure that conditions adverse to quality such as failures,
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malfunctions, deficiencies, deviations, defective material and equip-
ment and nonconformance are promptly identified and corrected.
10 CFR 50 Appendix B Criterion V states: Activities affectinJ quality
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shall be prescribed by documented instructions, procedures or drawings,
of a type appropriate to the circumstances and shall be accomplished in
accordance with these instructions, procedures, or drawings.
Instruc-
tions, procedures, or drawings shall include appropriate quantitative
or qualitative acceptance criteria for determining that important
activities have been satisfactorily accomplished.
Hatch procedure 10AC-MGR04-0, Deficiency Control System, step 8.2
states significant conditions adverse to quality will normally require
initiation of a Deficiency Report (DR). During the operations Phase of
plant Hatch, the conditions described in Attachment 1 shall be
considered Significant Conditions adverse to Quality.
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Attachment 1 of 10AC-MGR04-0 states that negligence or disregard of
management policy defined in administrative controls or procedural
requirements is a significant condition adverse to quality.
Contrary to the above, when it was determined that the replacement
wedge for valve IE11-F004A did not fit the original stem, the stem was
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ground down to make the replacement wedge fit.
This modification of
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the original stem was accomplished on the verbal authorization of the
maintenance supervisor only.
No deficiency report was initiated to
document that the replacement wedge did not correspond tn the as-found
condition of the valve or that modification of the original stem had
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been accomplished by disregarding the administrative controls and
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procedural requirements of the Hatch Maintenance program.
This is
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identified as a Violation 50-321/86-08-01, Failure to implement main-
tenance controls and document conditions adverse to quality.
Review
of this violation is continuing, therefore, it is not included in the
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b.
Maintenance Work Order 1-85-7217 worked the IE11-thermal relief valve
on the RHR side of the "B" RHR heat exchanger. The inspectors reviewed
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the work package associated with this work and noted no discrepancies
in the paper work provided for review.
Per the work package, the valve
had been removed, repaired, reinstalled and tested in accordance with
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approved procedures.
Review of the RHR Piping and Instrument Diagram
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determined that there are two thermal relief valves associated with the
RHR heat exchanger. One relief valve is located on the RHR side of the
heat exchanger and one relief valve is located on the RHR service water
side of the heat exchanger.
The inspectors inspected both relief
valves.
The RHR side relief valve did not appear to have been worked.
The RHR service water side relief valve appeared refurbished and had a
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valve leak repair yellow tag that referenced MWO 1-85-7217.
When
informed by the inspectors that the wrong thermal relief valve had been
repaired by MWO 1-85-7217 the licensee verified that the thermal relief
valve on the RHR service water side of the "B" RHR Heat Exchanger had
been worked instead of the thermal relief valve located or. the RHR side
of the heat exchanger as required by MWO 1-85-7217.
Failure to properly implement the maintenance program as defined in
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Administrative Procedure 50AC-MNT-001-005, Maintenance Program is
identified as a Violation 50-321/86-08-02, Failure to properly imple-
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ment existing plant procedures.
c.
Maintenance Work Order (MWO) 1-84-5742 worked the limitorque operator
on valve IE11-F1038, one of the RHR Heat exchanger vent valves. This
MWO required the perfomance of procedure 52GM-MEL-022-05, Limitorque
Valve Operator Electrical Maintenance.
Section 7.9 of procedure
52GM-MEL-022-05 performs the preoperational set up and test of the
limitorque valve operator.
Review of the completed work package
revealed that steps 7.9.13.7 through 7.9.13.17.1 were not performed
during the performance of procedure 52GM-MEL-022-05.
Section 7.9.13
performs the Electrical Circuit test of the limitorque operator prior
to the operational test conducted in Section 10 of procedure
Procedure 52GM-MEL-022-0S did not allow for the omission of steps
7.9.13.7 through 7.9.13.17.1.
Technical Specification 6.8.1 requires that written procedures be
established, implemented, and maintained covering maintenance and
surveillance activities.
Failure to properly implement maintenance
procedure 52GM-MEL-022-OS is identified as another example of Violation
50-321/86-08-02.
d.
Inspector Review of Maintenance History records showed that valve
1E11-F004B had its wedge replaced in 1981 by Maintenance Work Order
1-81-3328.
Review of the work performed revealed that a replacement
wedge was obtained from the same purchase order used in the replacement
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of the wedge for the IE11-F004A valve.
The inspectors expressed
concern that the same "T" head type stem may have been originally
installed in IE11-F0048.
The MWO package did not identify a problem
between the stem and wedge fitup.
This item is identified as
Unresolved Item 50-321/86-08-03 Determine actual maintenance performed
on valve E11-F004B in 1981, and must be resolved prior to Unit 1
startup.
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Within the areas examined, two violations and one unrenlved item were
identified.
6.
Management Meeting
On March 13, 1986, a management meeting was held between GPC,and the NRC in
the Region II Office.
The meeting was attended by senior GPC management,
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Crane Company Management, and Region II Management and staff.
The purpose
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of the meeting was to discuss the apparent lack of control in the valve
maintenance program, at Plant Hatch, based on the findings previously
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addr.cssed in this inspection report.
J. T. Beckham, Vice President and General Manager for Nuclear Generation,
opened the meeting for GPC by discussing their policies in regard to
Regulatory Requirements and Quality Assurance. Additional discussions were
introduced concerning GPC effort to increase the maintenance staff in order
to reduce the number of contract personnel currently required for mainte-
nance.
In addition, Mr. Beckham, addressed the ongoing procedure upgrade
program.
T. A. Seitz, Manager of Maintenance for Plant Hatch, lead the
discussion concerning GPC management systems which ensure quality work
and addressed the specific items of concern identified during this in-
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spection.
Mr. Beckham then closed the meeting with a summary and
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indicated they would look further into the concerns identified in
the maintenance program.
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