ML20235E314
| ML20235E314 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 03/18/1988 |
| From: | Brown W TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML082340470 | List:
|
| References | |
| 80200, 80200-V08-R06, 80200-V8-R6, NUDOCS 8902210308 | |
| Download: ML20235E314 (193) | |
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1 1 4 EMPLOYEE CONCERNS SPECIAL PROGRAM VOLUME 8 QUALITY ASSURANCE CATEGORY SUBCATEGORY REPORT 80200 INSPECTION l l l l UPDATED TVA NUCLEAR POWER k:- ... I t ~ g221030s390206 p ADOCK 05000259
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y--. D ] _g s 1 r TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM i i REPORT TYPE: Subcategory REVISION NUMBER: 6 1 !~ TITLE: Inspection PAGE 1 OF 143 l I REASON FOR REVISION: l To incorporate SRP and TAS comments. j Revision indicators in right margin indicate changes i 1 1 ^ l 1 PREPARATION PREPARED BY; W A. m .lj 3.]- g g I D dSIGNA1URE DATE l I i REVIEWS PEER: %Aa 34hr 3 6URE ~DATE TAS: be Ud&m s/3 48 i Q SIC ATURE I DA/E CONCURRENCES CEG-H: [m, )1/69 3!/[N SRP: SIGNATURE DATE SIGNATURE
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?I5hSintn i% ECM MANAGEq l l 0M E -MANAGER OF NUCLEAR POWER DATE l CONCURRENCE (FINAL REPORT ONLY) MSRP Secretary's signaturo denotes SRP concurrences are in files. 5866T i
't _ EXECUTIVE SUMMARV Subcategory Report 80200 ) 1 i " Inspection" j i." l I.
SUMMARY
OF ISSUES t I There were 123 concerns in this subcategory which were grouped into 44 issues for evaluation. Sixteen of the issues were determined to be I generic and 28 were determined to be site specific. The issues were evaluated under the following four elements: inadequate receipt c' inspection; procedures / inspection criteria; incomplete / inadequate l inspection; and inspection responsiveness. Evaluation results fell into i the following classifications: Class ' Issues Per Class l A-Issue cannot be verified as factual 12 l l l 8-Issue was factual but did not 6 describe a problem C-Issue was factual and identified a 14 problem, but corrective action was i initiated before the employee concerns i evaluation of the issue was undertaken D-Issue was factual and identified a 12 problem for which corrective action was initiated as the result of an employee concern ovaluation II. MAJOR FINDINGS 6 The evaluations conducted for this subcategory indicate that many of the inspection and test procedures used by TVA had deficient inspection and acceptance criteria. Of the 26 issues that were determined to represent -l page 1 of 4 e __.__A-____ "' ' ' - ~ - - - - - - - " ~ ' - "
.1 . probisms, 20 contsinnd soms aspset of daficient procedures, Proceduras were identified that were unclear, had conflicting requirements, and did not address all regulatory and design requirements. Examples of the types of procedure deficiencies identified include: Failure to include procedural requirements for: receipt inspection of warranty parts; calibration of certain measuring and test equipment; static head pressura considerations during hydrostatic testing; inspection of bends or exposed threads in conduit; compression fitting installation; and inspection of conax connectors for wire bend radius, torquing and use of grafoil sealant. Unclear procedural requirements for: concrete and anchor bolt 1 perpendicularity inspections; dry film thickness measurements of paint; some visual weld inspection attributes; and hanger location inspections. j l \\ Many of the procedure deficiencies described in this report had been i previously identified and corrected by TVA. However, there was no requirement to evaluate the impact of procedure deficiencies on prior q installations and determine whether reinspection and/or rework might be 1 necessary, j 1 i The issues evaluated in this subcategory did not require a complete evaluation of all of the TVA procedures for implementing the quality -i assurance program. However, the procedure problems identified are i s consistent with the results of evaluations in other quality assurance subcategories and indicate a need for improvement in assuring.that working documents such as proc 6dures, instructions, and drawings are clear and consistent and contain all appropriate requirements. e 2 of 4 5 e W q
w w III. Collectiva Signifiernce of Maior Findings I ~. The deficiencies identified in this subcategory:have contributed to some i t 1 of'the significant problems currently being addressed and resolved by TVA. Examples include the cable installation at WBN, welding, and j ins t rumentation. Because TVA's inspection procedures did not fully I' implement regulatory and design requirements and TVA commitments and in i some cases did not keep pace with the evolution of nuclear industry {' practices, substantial reinspection and reverification programs are now required. Individually, the impact of deficiencies in the inspection program varies. Some have had no impact, others have contributed to the need for substantial hardware rework, repair, and replacement, and some resulted in questions regarding the capabilities of inspection personnel. IV. Cause of Major Findings In general, the problems identified in this subcategory resulted from policies and procedures that did not adequately address inspection requirements as opposed to inadequate inspector performance. In a few cases, inspectors were not adequately trained or did not follow procedures, but this was not judged to have been the principal cause of problems. This tends to confirm the conclusion of QA subcategory 80300, " Quality Assurance Personnel" and indicates that, with a few exceptions, deficient inspection resulted from the tools provided inspectors (such as inspection requirements and acceptance criteria), rather that personnel-inadequacies. t Management in engineering, construction, and quality assurance did not establish and implement a process to consistently define all requirements, ensure that they were translated into working documents, coordinate procedure requirements between and within divisions, and provide for feedback to ensure that as requirements changed or as problems-were identified, procedures were kept current and consistent. 3 of 4 6 -4 p
e 3 Design output documents from engineering, which were the basis for many inspection procedures and practices, did not reflect all requirements and commitments in governing documents such as codes and standards. In construction and quality control, engineering requirements were not always adequately translated into working procedures and instructions. In quality assurance, some requirements were not contained in quality assurance manuals and quality assurance audits did not, therefore, result in the identification and timely correction of problems. Additionally, i the review and accountability process between and within divisions was weak which caused problems with consistency, and resulted in a situation where problems identified and resolved by one division or branch were not always communicated to and resolved by others, l V. Corrective Action For Major Findings The specific cases identified either prior to or as a result of this evaluation have been documented and have been or are being resolved. Where necessary, reinspection programs for existing installations have been or will be accomplished, and evaluation of procedure deficiencies to determine whether reinspection / rework is necessary has been made a requirement. In a general sense, problems with the TVA procedure system were recognized and are addressed in the corporate nuclear performance plan. In this plan, TVA has committed to revising the procedure system. The nuclear procedures branch in TVA headquarters has been tasked with this responsibility and implementation is in progress. The procedure system being developed is a five tier system which includes corporate policies,
- 1 directives and, standards, and division level procedures and instructions to implement the requirements of the corporate documents.
In developing this procedure system, attention needs to be focused on eliminating the causes addressed in Section IV, above, by creating an effective process for requirement definition, user involvement, inter and intra divisional coordination and standardization, and effective feedback. a Page 4 of 4 1 1 e
TVA EMPLOYEE CONCERRS REPORT NUMBER: 80200. SPECIAL PROGRAM FRONT MATTER REV 3 PAGE i 0F viii ~ 1 Preface r~ 1 This subcategory report is cne of a series of repor.ts prepared for the j Employee Concerns Special Program (ECSP) of the Tennessee Valley Authority (TVA). The ECSP and the organization which carried out the program, the f Employee Concerns Task Group (ECTG), were established by TVA's Manager of i, Nuclear Power to evaluate and report on those Office of Nuclear Power (ONP) 1 employee concerns filed before February 1,1986. Concerns filed after that i i date are handled by the ongoing ONP Employee Concerns Program (ECP). The ECSP addressed over 5800 employee concerns. Each of the concerns was a formal, written description of a circumstance or circumstances that an I employee thought was unsafe, unjust, inefficient, or inappropriate. The mission of the Employee Concerns Special Program was 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, will be published only for those concerns directly affecting 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 were grouped into elements early in the program, but issue definitions emerged from the evaluation process itself. Consequently, some elements did include only 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 overview of element findings leads to an integration of information that cannot take place at the element level. r-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. l To make the subcategory reports easier to understand, three items have been placed at the front of each report: a preface, a glossary of the terminology unique to ECSP reports, and a list of acronyms. 4 Additionally, at the end of each subcategory report will be a Subcategory Summary Table that includes the concern numbers; identifies other subcategories that share a concern; designates nuclear safety-related, safety 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 which the issue raised by the concern is evaluated. t gg 4 I
3 3 TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200_ SPECIAL PROGRAM FRONT MATTER REV: 2 PAGE 11 0F 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 I l material control operations quality assurance / quality control welding l i engineering A 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 the 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. A 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. I For more detail on the methods by which ECTG employee concerns were evaluated and reported, consult the Tennessee Valley Authority 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 closecut of the issues raised by employee concerns.
TVA EMPLOYEE CONCERNS REPORT 1% UMBER: 80200-SPECIAL PROGRAM FRONT MATTER REV: 2 PAGE iii 0F viii ECSP GLOSSARY OF REPORT TERMS
- 1 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) l 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 result 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 significance 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 fix specific deficiencies or discrepancies revealed by a negative finding and, when necessary, to correct causes in order to prevent recurrence. criterion (olural: criteria) a basis for defining a performance, behavior, or quality which ONP imposes on itself (see also " requirement"), r element or element recort an optional level of ECSP report, below the subcategory level, that deals with one or more issues. emolovee 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. hw ab4,3e =
-v g TVA EMPLOYEE CONCERNS REPORT NUMBER 8020b_ SPECIAL PROGRAM FRONT MATTER REV 2 PAGE iv 0F viii evaluator (s) the individual (s) assigned the responsibility to. assess a specific grouping of employee concerns. findinan includes both statements of fact and the judgments '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") requirement a standard of performance, behavior, or quality on which an 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).
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~~,, ~ TVA EMPLOYEE CONCERNS REPORT NUMBER: 8020Q SPECIAL PROGRAM FRONT MATTER REV: 2 PAGE v 0F viii Acronyms AI Administrative Instruction l AISC American Institute of Steel Construction 1 [- ALARA As Low As Reasonably Achievable l i I ANS American Nuclear Society f" ANSI American National Standards Institute l ASME American Society of Mechanical Engineers f ASTM American Society for Testing and Materials AWS American Welding Society BFN Browns Ferry Nuclear Plant l BLN Bellefonte Nuclear Plant CAQ Condition Adverse to Quality CAR Corrective Action Report ) CATD Corrective Action Tracking Document CCTS Corporate Commitment Tracking System CEG-H Category Evaluation Group Head j CFR Code of Federal Regulations CI Concerned Individual CMTR Certified Material Test Report COC Certificate of Conformance/ Compliance DCR Design Change Request DNC Division of Nuclear Construction (see also NU CON) I 'd i +- g ,p.
m e s 1 TVA EMPLOYEE CONCERNS REPORT NUMBER 80200-SPECIAL PROGRAM FRONT MATTER REV: 2 PAGE vi 0F viii DNE Division of Nuclear Engineering DNQA Division of Nuclear Quality Assurance DNT Division of Nuclear Training DOE Department of Energy DP0 Division Personnel Officer DR Discrepancy Report or Deviation Report ECN Engineering Change Notice ECP Employee Concerns Program ECP-SR Employee Concerns Program-Site Representative ECSP Employee Concerns Special Program ECTG Employee Concerns Task Group EEOC Equal Employment Opportunity Commission EQ Environmental Qualification EMRT Emergency Medical Response Team EN DES Engineering Design ERT Employee Response Team or Emergency Response Team FCR Field Change Request FSAR Final Safety Analysis Report FY Fiscal Year GET General Employee Training HCI Hazard Control Instruction HVAC Heating, Ventilating, Air Conditioning II Installation Instruction h INPO Institute of Nuclear Power Operations IRN Inspection Rejection Notice b
v- - g TVA' EMPLOYEE CONCERNS ' REPORT NGMBER: 80204 SPECIAL PROGRAM FRONT MATTER REV: 2' PAGE vii 0F viii L/R Labor Relations Staff i M&AI Modifications and Additions Instruction l I j MI Maintenance Instruction MSPB Merit Systems Protection Board 1 \\ l MT Magnetic Particle Testing 1 NCR' Nonconforming Condition Report NDE Nondestructive Examination I NPP Nuclear Performance Plan NPS Non-plant Specific or Nuclear Procedures System NQAM Nuclear Quality Assurance Manual NRC Nuclear Regulatory Commission NSB Nuclear Services Branch NSID Nuclear Safety Review Staff NU uoN Division of Nuclear Construction (obsolete abbreviation, see DNC) NUMARC Nuclear Utility Management and Resources Committee OSHA Occupational Safety and Health Administration (or Act) ONP Office of Nuclear Power OWCP Office of Workers Compensation Program l PHR Personal History Record PT Liquid Penetrant Testing QA Quality Assurance QAP Quality Assurance Procedures QC Quality Control QCI Quality Control Instruction l
__ y _ _ ) TVA EMPLOYEE CONCERNS REPORT NUMBER: 60200. l SPECIAL PROGRAM j FRONT MATTER REV 2 PAGE viii 0F viii i QCP Quality Control Procedure j .1 QTC Quality Technology Company RIF Reduction in Force RT Radiographic Testing SQN Sequoyah Nuclear Plant SI Surveillance Instruction I SOP Standard Operating Procedure SRP Senior Review Panel SWEC Stone and Webster Engineering Corporation TAS Technical Assistance Staff i T&L Trades and Labor TVA Tennessee Valley Authority l TVTLC Tennessee Valley Trades and Labor Council j UT Ultrasonic Testing VT Visual Testing i WBECSP Watts Bar Employee Concern Special Program WBN Watts Bar Nuclear Plant WR Work Request or Work Rules WP Workplans j i I .J
-... v ~1 ,] a - l Table of ContonLu Page Number \\ 1.0 CHARACTERI2ATION OF ISSUE 2 4 2.0 EVALUATION ME1H000 LOGY 4 3.0 FINDINGS t' - L4 l t l 3.1-Inadecual.e Receipt Inspection. 3.1 -.1 No Receipt Inspection Group 4 J ~- 7 ~ 3.1.2 Inadequale Receipt' Inspection of'CSSC Ilums. 3.2 Procedures / Inspection Criteria Ib l (.. 3.2.1 TVA Does Nut ~Have Adequate Control'0Vor the 15 l i Quality of Specific Vendor Wolds 3.2.2 TVA Does Not Have Adequale Controls Over the 20 I Quality'of Instrument Fittings Occause of-f Inadequal.e Procedurus i i 3.2.3 Some of TVAs Quality Assuranco Procedures 24 Are Lacking Acceptarn.e Criteriu 3.2.4-Procedures Used for Quality inspections Have 27 Cun f li c t.i ng, Unclear, and Incumplule Acceptanco Criteria 32.5 Noticos of Indications and Maintenance Requests 32 Do Nul. Have A Proper Truck ing Gyul.um 3.2.6 Excessive and Uncontrolled Procedural Ruvisions 34 and Drawing Revi., ions Havw Caused Cunfusion. For The Craft 3.2.7 Supplemental Inspection Criteria Utilized By 37 I Inspector s Are Nul. Out.umant.ed-un Thuir Ruports 3.2.8 Procedurus May Havu Ueen Violated When No meg / ohm 39 f. Tun tu Were Perfonned on Low Voll.ago Cablo and ' Wedge Bolts Wore Installed Through Rubar t. 3.2.9 The Procedure Ouscribing The Ai; wable Deviations 41 From the Specified Dry Film Thicknoss is Sometimes Used Incorrectly b d + 4 9 1
q ) n i Tablo of Contents (con't) 1 Page Number ^ 3.2.10 Electrical' Inspectors Get By Only With The Help 43 j Of Procedures and Because of Their Inexperience i Sometimes Accepted Unevenly Bent Conduit and { Conduit having Too Many Exposed Threads At j The Joints 3.3 Incomplete /Inadeauate Inspection 45 j l 3.3.1 Inadequate Cable Pulling Program 45
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Electrical Inspectors Impeded By Craft 50 From Performing Inspections 1 I 3.3.3 Inspection Performed Out of Sequence 54 l l 1 3.3.4 Hangers Installed In the Wrong Location 54 ( l 3.3.5 Inspectors Cannot Calculate' Torque Value 56' ) Conversions When Using Extensions l 3.3.6 Num9rous Incidents of Failure to Follow 59 l Procedures 3.3.7 Engineering Giving the O.K. To Accept 62 Equipment by Waiving Required Inspections 3.3.8 Inspectors' Job Attitudes and Behavior 65 IR6 1 Questionable l 1 3.3.9 Electrical Inspections Inconsistent and/or 67 Not Performed i 3,3.10 Electrical Inspection Results Not 72 Documented 3.3.11 Installation of Galvanized Junction Boxes 73 3.3.12 Nonconforming Instrument Lines 74 l (slope / cleanliness) l -1 3.3.13 Instrument Settings Falsified or Not 76 Documented 3.3.14 Walkdowns Are Not Adequate Enough to 78 Identify Deficiencies 1 b
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Table of Contents (con't)- Page Number 3'3.15 Instrument Panel Rejected Due to Bolting 80 Tolerances j 3.'3.16 Annulus Rack Piping Not Inspected For Thermal '80 Expansion and Seismic Movement. 3.3.17 Inspection and Testing of 2-FCV-0063-83, -8. -11, 82-
- 185, 186, 2 FCY 072-40 and 41 Not Performed t
Or Incomplete Before System Turnover - 3.3.18 Required NDE Not Performed 83 3.3,19 "Information Only" Drawings Deing Used In, 84 i Lhe Field For, Performing Inspections l 3.3.20 Reject Rate Low For Civil Discipline 85-1 3.3.21 Improuer' Measuring Melhudu used During 86 Inspection of Equipment 3.3.22 HVAC Due t GupporL Inspuct iuns Woro Purfor mud 87 I Defore The Issuanco.of the Oouign Drawings 3.3.23 Inupectors Are Nul Consistent in InLurpratin<3 89 Established Acceptanco Criteria 3.3.24 Empluyves IniLioling Chuckliutu WilbuuL 92 Performing Work 3.3.25 Field Inspectoru Inspoct to Procudures 93 ) I 3.3.26 QC Inspection im Inadequale 93. l 3.3.27 Inadoquate Installation of Conax Connectors 94 3.3.28 Piping Inspections Not Purformed 96 I l 3.3.29 Anchor Pull Test Result s Falsified by 98 l Craf t and Inupoci, ion Pe rsonnel I t 3.3.30 Reinspected Items Are Inspected by Less 99 Qualified Per vunnel 3.3.31 Hydro Test Packages Not Properly Filled Out 99 and Reviewud 1 -. + U. a w.
i Table of Contents (con't) Page Number 3.4 Inspection Responsiveness 103 3.4.1 Untimely Response by QC personnel to Requests 103 From Craft to Perform Inspections 4.0 COLLECTIVE SIGNIFICANCE 105 5.0 ATTACHMENTS 106 Attachinent A, " Subcategory Suiminary Table and 106 List of Concerns" Attachment B, " List of CATDs Issued" 106 l l i l l e.d
m TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 I SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 2 0F 144 i a 1.0 CHARACTERIZATION OF ISSUE j r' l The Inspection Subcategory consists of 123 concerns ovaluated under 44 issuus. 16 issues were generic and 28 issues were sile-specific. These j 4 I l issues wore grocped in the following four elenients: 1.1 Inadequale Receipt Inspection 1 ) I This element contained issues related to the receipt inspection { group and receipt inspection of CGSC items. l } i 1.2 procedure / Inspection Criteria This element contained issues related to TVA control ove,r the quality I j uf specific vendor wolds; TVA contrulv ovur the quality of instrument I i fittings; acceptanco criteria in TVA's quality assurance proceduro; I l procudur eu used fur quality inspectiunu; the tracking syutem for i Noticos of Indications and Maintenance Requests; procedure and drawing IR6 revisions; supplemental inspection criteria utilized by inspectors; I procedure violations regarding meg / chm tests on low voltage cable and I wedge bulls inutullation; incorrect use of thu procedur e for 1 allowable deviations in specified dry film thickness measurements of I f coalings; and eluel.rical inupact.or's aus.uplanco of unovonly bunt I conduit and conduit having too many exposed threads at the joints. 1 l l i i 1.3 Incomplele/Inadoquale Inupectiunu i 1 This element contained issues related to the cable pulling program; electrical inspectors impeded by craft from performing inspections; inspections performed out of sequence; hangers installed in tho l l wrong lucal. ion; inupectors cannot, calculate Lurquu value conversions [_ when using extensions; numorous incidents of failure to follow + m 'd 4
ur-I TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 1 PAGE 3 OF 144 procedures; engineering acceptance of equipment; inspector's job l aLL1Ludes and behavior; electrical inspections inconsistent and/or 1 not performed; electrical inspection results not documented; 1 installation of galvanized junction boxes; nonconforming ins trument lines (slope / cleanliness); instrument settings falsified or not documented; walkdowns are not adequate enough to identify 1 deficiencies; instrument panel rejected due to bolting tolerances; j annulus rack piping nul inspected for thermal expansion and ueismic j i movement; inspection and testing of value numbers 2-FCV-0063-83, -8, i l -11 -185, 186, 2 FCY-072-40 and 41 was not performed or was incomplete before system turnover; required NDE not performed; j " Information Only" drawings being used in the fiuld for perfor ming inspections; reject rate low for civil discipline; improper i mousuring methods used dt.. ring inspection of equipmont; HVAC duct support inspections were performed before the issuance of the design i I drawings; inspucLors are not consistent in inLorpreting established acceptance critoria; employees initialing checklists without per forming work; field inspectors inspect to procedurus; some QC f l inspection is inadequate; inadequate installation of canax I connec to ru ; some piping inspections not performed; anchor pull Last i i results falsified by craft and inspection personnel; reinspection by l leus qualified personnel than original inspectiun; hydro lost l packages not properly filled out and reviewed. 1.4 Inspection Responsivenen Thic element contained issues related to untimely response by QC per sonnel to requeslu from craf L Lo perform inspections. The evaluated issues resulted in the following conclusion classificativas: 12 is*:"es wer e not verified as factual (Class A); six issues were factually accurate, but what they described were not problems (Class 0); 14 iuuuus were factual and identified problems but corrective action for the problems had been initiated before .J
v n \\ TVA EMPLOYEE. CONCERNS REPORT NUMBER: 80200. SPECIAL PROGRAM REVISION NUMBER: 6 I .PAGE 4 0F 144 the employees concerno evaluation of the issue was' undertaken (Class. r C); 12 issues were factual and. identiflad problems for which corrective action has been, or is being, taken as a result of-employee concerns evaluations (Class 0), i 2.0 EVALUATION METHODOLOGY i General Evaluation The Employee Concern File, Nuclear Safety Review Staff (NSRS) Filo, and Quality Technology (QTC) File were researched fur portinunt information. A review was also performed of 10CFR50 Appendix 0, Final Safety Analysis Reports (FSARs), TVA Tupical Report, Nuclear Quality Assurance Manual (NQAM) and other Quality Assurance (QA) Program documents to establish Lhe requirements and criteria relating Lu lhe issues Interviews wuro held with personnel knowledgeabic of procedure requiremonto and of actual I installation and field verification actions rolalud to the issuus. 3.0 FINDINGS i ( 3.1 Inadocuato Receipt Inspection 3.1.1 Issue - Nu ReceipL Inspection Cruup. The Quality Recuiving Group was not established until three years ago/ April 1982 (IN-85 145 001; IN-86-011 001A) (Gite spucific - WBN) e-a . = e w-m._-._--
v I .) TVA EMPLOYEE CONCERNS' REPORT NUMBER: 80200 1 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 5 0F 144 Specific Evaluation J l This issue was ovaluated at WBN. I i ) ~ i The. following documents were reviewed for applicability to Lhe isuue: 'TVA Division of Constr . ion Quality Assurance Procedure (QAP).7,01, Revision 0, " Receiving Materials, Parts, and Components," and TVA Division of Construction Quality Control Procedure (QCP).1.6, Revisions O through 8, " Receipt, Inspection, Slurage, Wilhdrawal, and Transfer of Permanent Material", and the Nuclear Power Plant Componentis Manual (NCM), Revisions 0, 8, 9, 11, and 12 . Discussions wero held.with current Materials Inspection Unit ) personnel and their.uperviuvr, assistant quality supervisor for Civil, Welding, and Hangers, and former Responsible - Engineering Unit (REU) reprouonLutivus who had parformed receiving inspection activities prior to April 1982. ~ ? A randum survey of Receiving Repurls, Fur m 209, was conducted for various types of cons truction matorials, 'i.e., civil, i met.hanical, and electrical Lu determine wholhur these' items had documented evidence of propor receipt inspection as I required by the procedure. IR6 t Discussion The WBN Final'Safoty Analysis Report'(FSAR) commits to receipt inspection by invoking the TVA Tupical Report un QA 1 (TVA-TR-1-75A). The commitment was' implemented through-lR6 i varivuu Quality Assurancu' Program Procudures (QAPPs), Quality Assurance Proceduros (QAPs), and tho' NCM. Sito implementation al WBN wau-through WBN-QCP 1.6, That
n-y TVA EMPLOYEE CONCERNS REPORT NUMBER: '80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 6 0F 144 f procedure. required ' warehouse personnel to roccive and account for items on a " Receiving Report" (TVA Form 209). In cases i I involving " permanent material," REV personnel.were notified Lo inspect the material and indicate acceptance by signing Form 209. When " code items" were received, REU personnel were. notified and performed the required inspections -in accordance with'TVA Form 10084, " Inspection Checklist " r Acceptance was indicated by signing both Form 10084 and Form 209. A random survey Qf documentation for various items received I from 1975 to 1982 was ' per formed to determino whether the IRS documentation provided evidence of compliance with WBN -QCP 1,6 and section 3.6 of thu NCM. During the } documentation survey, it'was observed that not all " code itemv" had an inspect.iun checklis t allached Lu Lho Form 209. 1 Revision 0 of the NCM required that a checklist be utilized, but did not specify a particular form to be used. Latur revisions of the NCM were not availableEin the Records ~ Information Management Gyulem (RIMS) at the time of the QACEG evaluation. Missing revision 1 through 7 and 10 have l inhibited the evaluation lo Lho oxlent that the time of incorporation of Form 10084 " Inspection Checklist" is unknown. Therefore it is unknown wholhur ur not thu missing " Inspecting Checklists" constitute a procedural violation on-Lhe part of REU personnel. -t-l ECTG Subcategory Report MC40800 was reviewed for relevancy to lhe iusue. The report concluded that receipt inupaction personnel had boon trained and certified in accordance with existing procedurwu from 1975 until the eulablishment of thu Materials Inspection Unit in April 1982. t s ) 4 I L_-_________ i
I s W TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 l PAGE 7 0F 144 Conclusion I 1 The QACEG evaluation concluded that the issue is factual, as stated, but what it describes is not a problem (Class B). Prior to the formation of the Materials Inspection Unit in April 1982, individuals frvm uach REU were responsible for j i performing receipt inspections of " permanent naterial" and l l " code items." Discussions with cognizant personnel who performed receipt inspections during the period indicated that the procedur es were utilized. However, as a result of the employee concerns evaluation, a problem was discovered fur which corrective action was initiated. Causes The cause of this problem resulted from a procedural violation, in that there was a failuru t.o maint.ain historical revisions to the NCM, which is a " life of plant" document. i l Currective oction 1 The Divi _sion of Nuclear A'ul4b;1-^2:_ -...e suavnj was assigned i j { L,h f gm T bu NCM (CTTD I 0: 2 1)U kha s 05'suarch a o recov ar the IR6 i psing d and DNQ ueu &~ lem as seing I m; significant an issued Nro rnD O' ^^2 C. lou univ Uill remain I i i apen unLil the CAR has been acceptably closed, I l 1 3,1.2 Issue - Inadequate Receipt Inspection of CSSC Items j i 1 Malerials liulud as " Quality," " Critical Oystems, Structures, and Components" (CSSC), or otherwise required to be within l 1 I i f
~ TUA EMPLOYEE CONCERNS - REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 8 0F 144 - I - l r i the scope of the Quality Assurance Program, r;tay have been Inadequately inspected upon receipt and may havo been r-installed without inspection and documentation as requirod-by the QAP (WBM-150, WI-85-100 031 and IN-86-011+0018). l { (Generic-WBN-SQN) i Goecific Evaluation i This issue was evaluated at WON, SQ'N, BFN, and DLN. - l i The following documents were reviewed for applicability to the issue: American National Standards Institute (ANSI) N45.2.13, " Quality Assurance RequiremenLu for Control of Procuromunt, of Iloms and Services for Nuclear Power Plants"; l TVA Nucluar Powor PlanL Compo tents Manual (NCM), Rovision 0, 8, 9, 11, and 12, section 2.6, " Receiving Inspection, Gloring, PreservaLium, and Iuvulng of Codo II,ums," und socLion 9.1, "QA Records", QAPP 7, Revision 0, " Control of i Pur chavud Material, Equipment, and Gervicou"; QAP 7.01, Revision 0, " Receiving Materials, Parts, and Components"; QCP 1.6, Revision 0, through 8, "Ruceipt, Inspection, Slurage, - Withdrawal, and Transfer of Permanent Maturial"; AI-5.2, f Revision 12; AI-5.1, Revision 19; QCI-1.00, " Quality Assurance Records"; 0F 16.4, Rovision 0, " Material, l CumpunenLu, und Gpare Parls Receipt, Handling, Glorage, Issuing, Return to Storeroom, and Transfor"; QCI 1.1, Revision 0 2, "ReceipL Inspection"; BNP-QCP 1.1, Revision 10,- " Receiving Inspection"; BLA-9.2, Revision 12 and 13, "Roccipt Inupaction"; SQA 45, " Quality Control uf Malorial and Parts l i and Services";- AI-11, " Receipt. Inspection, Nonconforming l l I L 9 MD M4 g e 2____-__-_-___
m 1 l l l TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM I i REVISION NUMBER: 6 I PAGE 9-OF 144 l Items, QA level / Description. Changes and Substitutions"; NQAM, part III Section 2.1, " Procurement of Materials, Components, Spare Parts, and Servicos"; TVA memorandum, " Receipt Inspection of QA Equipment Supplied by Prime Supplier at no L cost to TVA", (T16 851206 949) December 6, 1985; Informal l Concern Report "W8N 158" dated August 7, 1986. 1 Discussion I The portion of the issue that deals with procurement specificatluns, drawings, and vondor documents not being in accordance with as-built or as-delivered configurations, and inadequate TVA review of vondor work has buon addrossed in QACEG Subcategory Report 80500. The portion of the issue dealing with inadoquate or lack of roccipt inspection for itums intended for installation, in CSSC was avaluated at all four uitos but found applicablo only to WBN and SQN. The issuo of no receipt inspection of some CSSC items originated as a result of an employee safoty concern 1 expressed by a Procurement Quality Assuranco employee on I l December 17, 1985. The uafoty concorn reforenced a TVA memorandum (T16 851206 949) which identified a problem with receiving General Electric supplied replacement parts for use in Class 1E electrical equipment. The memorandum indicated that existing AI's and the NQAM did not provide a method for receipt inspection and documentation of warranty parts l supplied to TVA, f ree' o f cha rg e, by a prime supplier. 1 WBN managomont initiated an investigation into the safety concorn, which consisted of interviews with cognizant management pursonngl to determine the scope of the problem. a C A-------------
se y __ TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200. ~ SPECIAL PROGRAM i REVISION NUMBER: 6 l PAGE 10 0F 144 \\ ? 4 As a result of the management investigation, four instances l were identified where vendor supplied warranty parts wure j r i i received without a contract. One was received in accordance with approval procedures, one was a non-CSSC' item, and two' were physically segregated and locked away by the. Electrical Maintenance supervisor-until proper receipt inspection.could r i j be performed. 1 The evaluation did not identify.any instances of material being installed at WBN without receipt inspection. I Discussion with cognizant personnel at SQN indicated that warranty parts supplied frue of charge by vundurs had been j received on sito in accordance with the requirements'of the original cuntractu. Reviuw of GQN prucoduros AI-11 and SQA45 indicated that, at SQN, these site procedures contain adequale provislunu Iur imphmunLulion vI ruculpL inspuc(luns. A discussion was hold with a SQN receiving inspecLor to dolermine the actual fluw of the uvurall recoipt inspection process. The individual stated that items not being i l inupecLed until they are ready for installation is not'a l l procedure violation becauso AI-11, paragraph 7. 2. 3, requires items to be inspeclud "Beforo use ur installation". The individual stated that, at times, items are requisitioned out \\ of the Power Stores Warehouse without required inspections being performed, however, these situations are identified through normal inspect.ibn processes and documented on CARS, DRu, or CAQRs as applicablo. The individual also stated that the Power Operations Training Cantor is curronLly revising thu receiving inspection training program t.o place more emphasis un the receipt inspection procous. 1 I ~ 9 O
e TVA EMPLOYEE CONCERNS REPORT NUMBER: 00200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 11 OF 144 A review was then performed of CAR, DR, and CAQR logs to determine whether there were documentud instances of missed ] receiving inspections. The review did identify some cases of l missed inspections along with cases where riencoriforming items weru discovered during inspection. Among the missed Irispections wau ari item transferred from WBN to SQN'und four .j 1 cases where items were issued for use prior to completion of - required receipt inspectiun. But no instances. wore identified where warranty parts had been installed without inupection SQN QA personnel, alurled by the number of nonconformances, initiated corrective action (retraining of Power Stores Warehouse Personnel). Discussion with the QA/QC supervisor indicates that the receipt inspection program at SQN is now operating as ruquired. The QACEG ovaluation at BFN dotormined thal (CSSC) Items required roceivitig inupuction in accordanco with DF16.4 "Malorial, Compononts, and Spare Parts Receipt, Handling, Slurage, Issuing, ReLurn to St.ureruum, and Transfor" dalod August 31, 1983 through Revision 5, dated April 28, 1987, or Quality Control Instructiori (QCI) 1.1, Rovision 0 through l Revision 2. These procedures required the Power Stores recei'pl inspector lu visually inspect itemu for shipping ,j damage and accountability, document the results on Form DF-48 (Malerialu Receipt Inspuction Roport) and Lu nullfy. Quality i Control (QC) Receipt Inspection. The QC Inspector performs requit ud inupuctions arid documenLu ruuulls on Form 8F-48 to signify acceptance of the item. It was noted that some dimunnional inspect. ions are performud with measuring tools j which are not calibrated, and are not part of the measuring and Lus t equipmont (M&TE) Progr am. 4 I I
~,- ~ i TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM j REVISION NUMBER: 6 r i PAGE 12 0F 144 I f A randem survey of various items in the receiving area was f performed to verify that the Forms BF-48 were being utilized as required by the implementing proceduro. 1 l L l Regarding items received without a contract and receipt inspoction, the issue was not found factual based on a review j of randomly selected Material Receipt Inspection Reports and more specific information from the Concerned Individual (CI) } Wds not available. l The evaluation of the issue at BLN includod discussions with (4) four cognizant personnel in the rocaiving group and Power l Stores. A review of DNP-QCP 1.1, Revision 10 through 14, dated September 7, 1983 through March 13, 1985, titled "Rocciving Inspection" and DLA 9.2, Revision 12 and 13, dated July 24, 1986 and March 3, 1987, titled "Rocoipt Inspoction" q provided details on what each item received on site must be ) inspected for. All items, including CSSC items and sparo parts must go through thu receiving department. l l i BLA 9.2, Rovision 13 states "Tho purpose of this instruction is to define the responsibilities and to establish the i controls for receipt inspection of all matorials, components, and spare parts including thoso procured for the critical ( structures, systems, and componoots (CSSC). This instruction t implements the NQAM Part III, Section 2.2 as it applies to receipt inspection." Receiving starts when an item arrives at the plant, before unloading or unpacking and proceeds through t.be process of inspections, marking, identification, and documentation prior to placing the item in storage or directly in its final location. Aftor the Itumu are unloaded s l (> t i __._.._._.________o
~m-l l TVA EMPLOYEE CONCERNS' REPORT NUMBER: 80200 { SPECIAL PROGRAM { l REVISION NUMBER: 6 l l l PAGE 13 0F 144 I i and unpacked another inspection is performod and_the j appropriate checklist is completed. The inspection is I completed to verify.that each' item is as specified by contract and thal duuumentation from the vendor is correct f and' adequate, I l l BNP-QCp 1.1, Revision 14, dated Ma'ch 13', 1985 ' states'in r 6.2.1 "All material and equipmont shall be inspected and. verified to moot the specified requirements as indicated.by the contract." Verification is also required to assure that IR6-the material meets the requirements of the various codes, I standards, specification or other spucific (TVA, NUC' REG 3, MIL-STD) specification requirements referenced by tho contract. In nume cases revisions to the vendor drawings i wure mado and approved by the TVA Source Inspector through l Engineering and the ilum was nul accepted without the proper Engineering Chango Notico. l A memorandum daled April 29, 1906 by T..L. Huward status f: hat the acting suporvisor.was contacted at BLN and af ter he interviewed maintenance supervisuru, he -felt that. thure was ~ nu problem in the rocciving department portaining to how items withuul contract.s w0uld be handled sincu warranty Itums are treated like now when they are received. They all go through the roceiving dupartmunt and Power Storus. BLA 9.2 gives Lho Power Stores Clark.the responsibilities to receive Level III (non-safety related) items and some non-ASME ltems. On April 6, 1987, the Power Stores Supervisor asked the Avslutant Qual 1Ly Control Manager, whether all CSSC items nooded to go through the Quality Control Inspecturu in receiving. The reply was that all CGSC items will go through'the QC Inspectors for roccipt inspection. Y W e
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 14.0F 144 I I Conclusion .f~ l The QACEG evaluation concluded that the issue at WBN.and SQW q is factual and' identifies a problem which had corrective i. action undertaken prior to the evaluation (Class C) As discussed, TVA management conducted an internal Investigation which identified instancos of vendor supplied I r l l warranty parts being shipped Lu WBN without contract authorization or TVA acceptanco documentation. However,- i actual installation of, any males-ial without receipt inspection was not verified. Section 2.1 of the NQAM has buon revived to address purchaso of spare and replacement-parts. AI-5.1 and AI-5.2 were also revised to address acceptancu of "no cout" replacement parts at WBN. Although replacement parts, covered by warranty, have always been received al SQN undur thu Lorms of thu original contract, SQN proceduros, AI-11 and SQA45, woro revised to j cover rucwipt inspwelion requirements for duch parts. Tho. i fact that items woro not always receipt inspected until ready fur installation was alluwed by AI-11. However, due to I instances where items were released for. installation prior to rucwipL inspwellun, waruhuusw purvunnel havo been notified to halt the issuanco of non-inspected items. Thw issuw was found nuL factual al BrN and BLN, although a j sido issue at BFN did require.correctivo action. CATO l l 00251 -8FN 01 nas luvuwd Lu document the usu of uncalibrated measuring dovices while performing dimensional checks at BFN. l l s L I i. 4 ) l. i
1 TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 l I PAGE 15 0F 144 I i Cause The cause of inadequate receipt inspection of CSSC warranty parts was that program requirements were not specified for these parts. Thorofore they were received without a contract or acceptance documentation. Corrective Action At WBN, Section 2, of the NQAM, Part III,." Procurement of Materialu, Components, Spare Parts, and Servicos," was. revised to address purchase of spare and replacement parts, i . additionally, AI 5.1 " Material ProcuremunL and Contrul," and AI-5.2, " Receipt Insp'oction of Materials, Components, and Spare Parts," were revised to addrusu accuplance of I replacement parts supplied by vendors at no cost to TVA. AT SQN, AI 11 and SQA 45 uwr e ruvisud Lu includu receipt inspection requirements for vendor supplied warranty parts. In addition, currecLive action in-the form uf retraining l Power Stores Personnel has taken place to heilt issuance of I uninsepcLud items. As a result of a side issue at BFN, Project Engineering - BFN has agroud to revise QCI-1,01, " Receipt Inupection,"Lo include references to Standard Practice 17.5 and the NQAM,Vulume III, Section 3.1. This r esponds to CATO-80251-BFN-01 and has boon concurred with by QACEG. -____m__--__ ___m___ __.2__
v TVA EMPLOYEE CONCERNS-REPORT EUMBER: '8020'0: SPECIAL PROGRAM. REVISION NUMBER: 6 PAGE 16 0F 144 .r 3,2 Procedures / Inspection Critoria c. k, 3.2.1 Issue TVA does rioL have adequate contrul ovur the quall'ty.of specific vendor welds, (JAN-85-001,'JLH-85-005, IN-85-001-005, l P' ~J 4 IN-85-007-003, ' IN-8 5-127-001,. IN-85-297-006, I IN 85 372-001, IN-85-657-001, IN-85-246-005, IN-85-852-001, IN-85-868-001, IN-85-960-001) (Cunwric ) Specific Evaluation l i This issue was evaluated at WBN, GQN, BFN, and DLN l l l The fullvwing documenLu wur u roviewed for applicability to 1 the issue: NQAM, Part I, section 2.7, " Control of Purchased Ilums and Services," and suction 2.10,'"Inupaction"; QTC Report IN-85-657-001; AI 5.2, " Receipt inspection of Materials, Compununts, and Spare Par ts"; QCP 4.13 FU & VM," FIL-up and Visual Mochanical"; QCP 4.13-FU & VC," Fit-up and Visual Civil";QCP -1.06, "RecwipL InspucLion vI Safuty' Related i ILems"; Process Specification 3 M.5.1,.Rovision 6, I "SputificaLion for examination of wold joints"; Proc'ess Speci fication 3.C,5. 4, Revision 2, "WBN Final Visual Wold I Cxaminallun"; Process Specification 3,C.S.4,-Ruvision 2, I' Addition 2, " Visual Weld Inspection".; NRC letter of July 24, i. 1986, " Report for additional.Informallun.concerning thu-Project Management Plan for the Department of Energy Weld EvaluaLion Projwcl for the WON, Unit 1 and 2" (A02860728012); ( TVA letter of December 5, 1986 to the NRC, " Response to NRC weld ing ques Livns;" GQN workplan 11777; Nundus tructivu Examination Procedure N-VT-4, " Liquid Ponotrant Examination"; ACME Suction XI, Division I, IWA 4000, 1980, Winter 1981 Addenda; ANSI B31.7, 1960 edition, Sunmier 1970 addenda; t-
-v TVA EMPLOYEE CONCERNS REPORT ~ NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 17 0F 144 Welding Project Report-WP-17-SQN, RO. In addition the-following vendor procurement contracts were reviewed: Bergen Patterson Hangers - Contracts 83014, 824160, and 820732; YUBA Heat Exchangers - Contract 821635; Julius Mock Escape 5 Hatches /Manways - Contract-86188; Westinghouse / Delta Southern Accumulators Contracts 54114 and 182062; Doors (various) - Contracts - 821144, 86331, 86100, 86267, 820423 and 85955; i Tanks Opebha Welding - Cuntract 822272 and CE Contract 75210. At BFN - Contracts 84410, 84876, and 90936 were reviwwed. AT BLN, Contractu 86289 and 823716 woro reviewed. Tu aid in the evaluation, discussions were hold'with SQN Quality Asuurance/ Quality Cunt.rul (QA/QC) personnel, t.ho Watts Bar (WBN) Quality Control Managor, an Assistant Quality Contrul Manager, a Quality control Gupervivor, two Welding InspecLars, and a former Materials Engineer, a Conior Malurials Engineur al the Quality Ausurancu Knoxvillo Of fice, a Bullefonto Nuclear Plant (DLN) Wolding Quality Control Guper v ivur, a GLN Hangwr. Engineering Unit Suporvisor, and a Browns Ferry (BFN) Assistant Quality Control Manager. Discussion Through investigation of this issue at WDN, QACEG'has dot.ormined that the wuld acceptance criteria contained in TVA inspection procedures are somewhat more stringent than those impuued on vendors and that t.hure iu no requirement fur receiving personnel to inspect components, saf ety-related - or nunuafuty relalud, for welding quality. .TVA's inspection of vundor components is normally performed by surveillance at thu vundur uhup, al some point prior.Lu shipmunL. In addition, although the acceptance critoria may be different, bulb Lhw vendor welding and TVA welding is required to bo in accordance with the applicable codo. --um,_.,c._
v y TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL' PROGRAM REVISION NUMBER: 6 i .PAGE 18 0F.144 Due to Employee Concerns which allegod questionable welding - r* at WBN, Units 1 and 2, the NRCJin their letter of July 24, 1986, (A02860728012), has requested that TVA provide-a detailed plan to addruss welds in vundur components. TVA's ~ {- response of December 5, 1986, (L44860737)~indiwated that the Division of Nuclear Quality Assurancu will perform an evaluation of vendor welds. It will be accomplished by-evaluating genwric employee concerns, past TVA Quality Indicators, and will considor-industry exporlonces with spucific vendors, In a discussion with thu WBN QC Manager, reinspection of vondor wolds will consider respectivo i population sizuu for various safety-rulated and non-safely I 8 welds identified in employeo concerns. IR6 Therefore the specific allegation that vendor wold accuptance criteria results in poor quality vondor wolds at WON will'bc determined by witw inspecLion pur uunnel, ' utilizing the i acceptance critoria in the various vendor procuromont cuntracts. I Some unsatisfactory vendor wolds-have boon identified on NCR 6345 for Employuw Concern IN-85-372-002 and NCR 6947, I Revision 1, for concern IN-85-852-001. The nonconforming condition citud in NCR 6345 is that " Contractor wolds for utiffuner platos on hatch cover appear to be undersized in places and have undurcut and overlap." 'The.NCR was l l l disposited as "uso-as-is" by TVA Engineering becausu the ' h halch location (RHR Sump)"-is no longer an untension of the reactor building primary containment and is not 4 safely -relalod. Thereforu, Lhv wolds are acceptable". The a disposition for NCR 6947R1 was not accepted by QC and romains open becauuw thu diuposillon was not adequately justified. O (~ 4 -______._-_____.m__
O TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 10 0F 144 The nonconforming condition, "some overlap and abrupt ridges at the too of the weld" relatos to TVA Procuss Specification 3.M.S.1, Revision 6, " Specification for Examination of Welds Ends." Thiu' weld is safety-related and the acceptanco standards stipulated in the contract in ASME Section III,. 1 Article NC 5000 requirev radiographic examination. Project Engineering, in stating that a nonconformance does not exist-only considered Lhu response from the primo-vendor,. Westinghouse that the tank moots the design acceptance vlundardu vel forth in Article NC 5000 which doos not address the radiography requirement. The issuu is generically applicable to BFN and BLN since thu i same vendor has supplied wolded components to those plants. Site QC personnel will perform an inspection of all welded components supplied by this vendor, Julius Mock and Sons, 1 Brooklyn N.Y., contract numberu; GFN-84410, 848/6, and 90936; BLN-86209, and 823716, to determino compliance with 1 code requirements. AL SQN it was alleged that cortain welds made by Southwostorn Engineering Cumpany (SECO) and National. Valve und Manufacturing Company (NAVCO) do not moet codo requirements. As stated in an unnumberud NSRS report, "Onsile Employee a Cuncorn Impact Evaluation," a survey was performod by a QC 1 Inspect.or, a SECO representative, and Lho TVA cognizant unginuur to identify the defective wolds. A total of'24 l weldu waru identified as requir ing ruwork. ~ SQN Work Plan 11777 was initiated and the affected welds were reworked. Verification of thw rework was performod by QC and documented in Lho Work Plan. The un-numbered NSRS ovaluation "Onsite Employee concern Impact Evaluation" indiculud ' that the concerned employco was notified of the repair work and the employee was satisfied, o-J
I e i l TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM' I REVISION NUMBER: 6 1 PAGE 20 0F 144 p The three NAVCO safety injection welds specified in this j issue were identified as 315D, 315E, and 316A. The welds ~' were located in Fan Room #1,: Unit 1, near valve 1-63-649'at the ceiling above the ladder access opening. Several f l photographs were taken by TVA Quality Assurance personnel uhowing actual weld conditions. The welds were delormined to be unacceptable in that they violated the visual.'acceptanco requirements of N VT 3, " Visual Examination." Maintenance Request A-561926 describes the rework performed to correct the idenLified conditions. Corrective Action consisted ' f o grinding areas identified as unacceptable and performing the r l necessary nondes Lructive examinations (LP & UT) requirud for I final acceptance in accordance with ANSI 031.7, 1969 Edition, Gummer 1970 Addenda. Work was completed on January 20, 1986, with ANI/ANII concurrence. A. part of the QACEG evaluation,'an inupuctor from the TVA Quality Control group and a QACEG Evaluator verified wcld idonLirication and perfvrmed a visual inspucLion of 1.he throu i welds to further substantiate corrective action and the j proper closure of the Maintenance Request. This reverification concluded that all items were acceptable and i that rework and reinspecliunu wure in accordance with the work instructions specified in the Maintenance Request. l l Conclusion i l The issue that TVA did not have adequate control over the quality of specific vendor welds lu factual-und prouonts a t i problem for which corrective action has been, or is being, Luken au a result of an employee concernu uvaluation (claus 0). As a result of this ovaluation it was substantiated that some unsalivfact.or y vendor weldu exiuL at UDN and SQN. -Tho potential for unsatisfactory vendor welds exists at BFN and ^
- OLN, 4
'i 4 ,,t.. u________________..
g TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 21 OF 144 Causes The cause of quality problems with vendor welds is the failure i of vunder control programs to result in complianco with I specific code requirements and inadequate monitoring of vendor IR6' shop performance by TVA to obtain pre-shipmunt compliance, i Corrective Action Quality Assurance - WBN has been directed by the NRC in their-I leLLur of July 24, 1986, Lo establish a vendor weld I reinspection program. As this program had not been IR6 implement,ud of the Lime of Lhis evaluallon, CATD 80203-WBN-01 I was issued. I Since then, the TVA Department of Nuclear Quality Assurancu had initiated a plan for addressing welds in vendor-mado componenLu, which includes research of vunder contracts, drawings, and specifications. A review has been completed of applicable CAQu, NCRu, CAT Team Reports, Audit Reports on vendor welds, and employee concerns. A population'of approximately 20 vendors huu been established wiLh field inspections soon to be underway. QACEG has accepted this response to CATO 80203-WBN-01. The disposition for NCR 6345 (accept-as-is) by construction unginouring only addresuud the uafuly staLuu of.the weld and I did not consider the actual weld condition. CATD 80203-WBN-02 lR6 wau issued. The response by TVA lo this CATO s talud that no I corrective action was required and that, although the condillon of thw weld had not been Laken into consideration originally, the validity of the disposition was confirmed by field inspection Lo verify that uubulantial weld was attaching the stiffener platos to the skin plates. This rwuponue was accupled by QoCEC.
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 22 0F 144 i The previously cited welds made by NAVC0 and SECO were determined Lu be substandard. Thouw welds were repaired and accepted. However, the Office of Nuclear Power (ONP) did not establish a uampling program for uthor welds made by NAVCO f and SECO. CATD 80201-SQN-01 was issued to track the problem. ONP responded to this CA1D stating that a Quality l Assurance Survey was conducted by TVA which covered the majority of SECO and NAVCO welding. SECO welds were repaired I 'i as required. The survey concluded that there was no indication I of an unsatisfactory performance record by NAVC0 beyond the IR6 I i specifically identified welds and further action was I j i unnecessary. The response has buon accuptud by QACEG. t l l I l The vendor that supplied welded components to WBN, Julius Mock & Sunu, also uuppliud welded cumponunlu Lu BrN and BLN. Thu respective QA departments for the two sites have been asked to deLermine Lhe acceptability of the vendur suppliud welds. CATO 80203-BFN-01 an {80203 BLN-O h issued addressing the need to t t6 "o nuet welds. Bo b re M nceu by the QA departments iI e f gy spection a nd issue CAQ's for TE: 3b685 3.2.2 T**"n - TVA does not have acuquate svou va vuur the quality of [ f instrument fillings because of inadequale procedures. The j l compression fitting installation program is inadequate due L Lo lack of adequale procudures and training of personnel i in installation and inspection. (XX-85-050-001, XX-85-050-003) (Ceneric) 1 Specific Evaluation This issue was evaluated at WBN, SQN, DFN and BLN. 5 F f % o u ,s. I
y_ e TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 23 0F 144 The following documents were reviewed to determine applicability to the issue: NSRS Reports I-85-329-SQN,. R-85-02-SQN/WBN, IN-85-795-001,.IN-85-795-002; Nonconforming Condition Report 6278; Significant Cundition Report 6278;. TVA Final Response.to the NRC (L55 860730-816); BLN BNP-QCP4.3, " Instrument Tubing Installation"j Awareneus Bulletin " Tube Fitting Awareness and Initial Training, "(L29 85-909 817); MTG-28, " Initial Tube Fitting Training," Revision 1; Process Specification 3;M13.1, " Specification for Installation and Inspection of Compression Fitting Joints in Mechanical Tubing Systems." In addition, the QACEG evaluation included discussions with personnel in Quality Assurance, Quality Control and Welding Enginuaring, Construction Superintendents, and a Mechanical Maintenance Supervisor. Discussion Quality Assurance controls as applied to the installation of instrument compression fiLLirigs havu buon the subject of numerous investigations at all four of TVA's nuclear sites. Results of these investigations are contained within formal reports such as NSRS Reports "I-85-329-SQN," "IN-85-795-001," "IN-85-795-002," and "R 85-02-SQN/WBN." NCR 6278 and Significant Condition ReporL SCR6278-S have been issued as a result of these reports. The significant condition reported was that compression fittings on instrument tubing were not installed in accordance with vendor inuLructions. Improperly ausembled fittings can result in a "line" seal which can be broken with the slightest movement, thereby causing joint leakage. To correct this situation and to respond to NSRS recommendations, TVA has:
- Evaluated the issue for generic applicability to all nuclear plants.
1 , nd w
4, v i 1 TVA' EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM . REVISION NUMBER: 6 PAGE 24 OF 144 ( l. 1
- Instituted formal training for craft and quality control personnel involved in installation and. inspection of
~' compression fittings.
- Acquired.the services-of Singleton Materials Engineering Laboratory lo analyze the reliability and safety of fittings which may not have been installed in accordance-
'l 1 with the manufacturers directions,'but which have achieved j 'loak tightness,. l i and l l
- Revised, or will revise,,the process-specification and all af fected drawings, procedures, and instructions relating to compression fitting installation.
) l Conclus' ion- ) i The issue of inadoquate controls for installing instrument compression. f1LLings is. facLual.and 'presunts a problum for f I s i which corrective action has beer,, or is being, taken as a 1 resull f amployee concer ns evaluation (class 0). l Cause The cause of TVA not having an adequate quality assurance I cuntrul program for the installation ins trument fittings, is the failure by engincoring and construction to specify I l e I i and provide adequale ins ta11alion/ ins pec tion ins tr uc t iuns IR6 and inadequato training of craf t and ' inspection personnel. I i Management also failed'Lo communicate lhe problum to Lho I different. sites which allowed it to remain uncorrected I 1, for an extended puriud of Lime. l i. i s
m TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION. NUMBER: 6 i PAGE 25 OF 144 Corrective Action NSRS Reports IN-85-795-OO1 and I-85-329-SQN provided the following recununendations : an engineering evaluation; initiation of an NCR documenting the condition; and the training of personnwl in the inslallallon and inspuction of compression fittings. Inadequate compression fitting installation wau also reported to the NRC under the rules of 10CFR50.55(e) via NCR 6270. TVA transmitted their final 10CFR50.55(e) reporL on Lhis subject to Lhu NRC on July 30, 1986. The above actions were taken by SQN and WBN management to improve compression filling inulallation. However, QACEG has issued CATD 80201-SQN-02 to ONP on September 12,-1986, to identify the lack of prucodural tv>iriirr - " _-t: for l k i ep 1ho Admi pis trati tion t-1 renc e to-the [ube filnrh wraiTurs auisito ouwd, MTu-MMT-79 for personnel involved with compression fitting installation. TVAv commiLment Lu lhe NRC Lo develup and issue MAI-29, " Instrument Tube Fitting and Installation," by August 15, 1986 was not accomplished, As a result, CATD 80201-SQN was issued to ONP to issue MAI-29. ONP replied that the SQN ModificaLiunu Group is the responsible organization. The Modifications Manager has stated that:
- 1) a memorandum
($02 861202 827) was transmitted to DNE requesting thuir evaluation of NCR/SCR 6278, 2) A procedure (MAI-29) will.be wrillen defining ruquiremenLu for installation of Lube f1Ltings at Sequoyah.
- 3) Retraining requirements will be established on a frequency of onu year for Modifications personnel and two years for Maintenance personnel. The CAP was concurred with by QACEG.
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v TVA EMPLOYEE COWCERNS REPORT BUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 26 0F 144 At DFN, in response to 0FN-CAR-800083, ONE issued Procedures MMI-174 " Replacement of Compression Fittingu," Revision 0, 7 January 14, 1987, and MAI-41 " Field Routing of Instrument Impulse Lines, Sample Lines, and Control Air Lines," Revision 0, December 2, 1986, to establish installation and QC inspection criteria for compression fillings The Knoxville Office of Engineering has written a draf t engineering specification (ER-8FN-EEB-001) for l instrumentation, which includos compression fittings which a will be coordinated with the walls Bar InuLrumentation Program. At BrN CATDs 80202-BFN-01, 02 and 03 were issued to the Of fice of Enginuar ing to addr ess pr oblums romaining in the compression fitting installation program. Although j pr ocudur e'., havu buen updalud and Lr aining cour uos i established, the installed hardware has not been reinspected I !.o wurify acceptable installation. IR6 Engineering has issued CAQRs DFP870014, DF0070305, and DFP870306 to evaluate and take corrective ucLion on generic NCR 6278. This action is in response to CATDs 80202-BFN-01, f and 02 and has buun concurred with by QACEC, In response to CATD 80202-DFN-03, BFN Enginocring has stated that CAQRs will be wriLLun to address similar pr oblems in Units 1 and 3. QACEG has concurred. At BLN, BNP-QCP 4.3, Revision 10 " Instrument Tubing Ins LallaLion," detailed the inspection critoria for thu installation of compression fittings. Revision 11 to BNP-QCP 4.3 deletud the requirement for inspecting compression l fittings. Thirtoon months later revision 13 of DNP QCP 4.3 reinstated the inupaction requirement. DLN Quality Assuranco must assure that there were no installations of compression
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 l SPECIAL PROGRAM REVISION NUMBER: 6 l l PAGE 27 0F 144 l fitt i i e o 1986, o - prouide doc vidence .,' i na 11 ' em were 1 1spected 4 g e-and ftowhat & a 'Ta +r +h = FA n2-OLN-31 was issued. The BLN-Quality Assurante DupartmunL rumponced that no I program problems existed either beforo or after the thirteen i month period and that all lines would be either hydrostatically I or pneumatically tested and thus prevent any compression IR6 fitting installation problem from going undelected. QA also I j provided a copy of BLN Training Modulo and craft training i reporL daled May 3, 1985 t.o demons trale adequale training of I craf t personnel during the period in question. QACEG has I concurred. I l A generic NCR, 6278 R1 was sent to all' sites, including BLN Engineering, citing possiblu compression filling installation-problums al all sites. BLN-Enginocring responded to the NCR by ulating that Lhe problum "Dowu Not Exiul" with no further explanation. As a result of the DLN-Engineering disposition t.o NCR 6278 R1, CATD 80202-BLN-02 was issued requesting an explanation to justify the answer to tho u Engineering repliu 78 ~ m L to BLN DNE and ons was ac >ptable b e save any cye awin s fr i c npressi 'q ys (No was by BLN l 0 C as runs IT QB-85-24, RIMS - C2 5). The corrective action plan was accepted. 3.2.3 Issue - Certain TVA Quality Assurance Proceduros are lacking acceptance criteria. The contention being that specific procedures do nut provido qualitative and quantitative values sufficient to perform adequato l inspections. (I 85 102 BLN, BNP-QCP 10.35 0, XX-85-102-006, IN-85-347-006, WI-85-046-02, IN-85-279-005, WI-85-013-004, XX--8 5-079 -001, QCI-1.31 86, IN-85-849-001) (Genuric) l 1 -1 Q---------____--._---_._-
u- ) TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 i PAGE 20 0F 144 i l Specific Evaluation l I .c This issue was evaluated at WBN, SQN, BFN, and BLN. The fullowing documents were ruviuwwd for applicability to the issue: BNP-QCP-10.1, " Preparation and Control of Quality f' l CunLrul Procedurwu and Construction Test Procei: lures"; General i Specification G-43, " Support and Installation of Piping { Systems in CaLugury/StrucLurus"; ASME Section II, Parts A, B, and C, 1974 odition; TVA Proceduro DF-16.4, " Material, j Compununlu, and Spare Parts Receipt, Handling, S tu rag o,. Issuing, Return to Storeroom, and Transfer"; ANSI N45.2; i Technical InuLruellun (TI) SOA; "ASME Section XI Pruservice a l Inspection Program;" NSRS Report I-85-547-WBN, November 13, 1905; WBNP-Quality Cuntrol Teul (QCT) 3.13, "Hydrus Lalic Pruusure Testing of Instrument Sensing Linos"; Concral 1 Specification C 37, " Testing and Balancing of Hoating, j 1 VonLilating, and Air Conditioning Systems"; and QTC 4.40, l l "Dalancing of HVAC Systems." Discussions war o hold with l ) Mechanical Quality Control personnel. I ) Diucussion In evaluation of this issuo numerous procedures wuru reviewed al all sites to determine if accuplance criLoria, quantitative values, and Quality Control certification requirement.u were includud (I-85-102-BLN). The prucedures reviewed, including DNPQCP 3.30, (BNP QCP 10.35-D) contained a ueetion 7.0, " Acceptanco Critoria," that describud thu applicable qualitative inspection attributos. Those prut.edures referencud appropriate upper -Liur documunlu and l were reviewed by Quality Assurance before issuance. 1
-m., TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 'SPECIAL PROCRAM . REVISION NUMBER: 6 PAGE 29 0F 144 1 1 In some casos, missing criteria reported by the concerned j employee was not required by governing docuinents; AGME f Section II has no visual examination requirements for a fabricator ur ins taller and therefore, TVA has no applicable proceduro (XX-85-102-006); the use of checklists as an inspecLion aid is not ruquired by upper-tier program requirements or lower-tior implementing proceduros (IN 85-347-006)..BLN, however, usus checklists extensively and WBN is in process of developing a Model Inspection Plan which will implement them; TVA nondestructive Examination Procedure (NVT-1) Part C, "VT-4 Visual Examination," paragraph C,4,2'"Verifical.lon of the Gelling" and C.S.2 of the same title, adequately explain range settings for mechanical and hydraulic snubburs', respoctivuly (WI-85-046-020), The actual rango for each snubber, however, is liuled un the support drawing; Quality Cuntrol Instruction, QCI-1.27, " Design Information Roquest - PreparaLivn and Documentation," implumentud in 1980, specified methods for numbering, filing, and logging DIRs (IN 85-279-005) but, was cant.elled in 1983 by Revision 3 Lv 1 Quality Assuranco Procedure, QAP 3.2, which stated, "in the l future, Field Change Requestu shall be used to obLain i additional design information"; and until Revision 6 was 1 issued Lu Quality ConLrvi Procedure QCP 1.47, in July 1985, no I accuplanco criteria for damaged robar oxisted or woro required I in u ite procedureu al WGN (WI-85 -013-004), because IR6 1 l nonconforming condition reports were issued for any damago I encountered. I Discussions were held with mechanical Quality Control personnel at OLN, Lo' determine if there has boun any pipe alignment problems caused by pipo movement, subsequent to final pipo locat. ion verification, with Lumporary supports 1 installed (XX-85-079 001). There had not been any instances
m v l TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 4 PAGE 30 0F 144 e \\ of pipe. movement during subsequent installation of permanent l l 1 s u ppo r ts. Addi tionally, DNPQCP-6.10. " Exposed Piping," j 1 correctly states'the requirements of. process specification 1 l ' G-43, " Support and Ins tallation of Piping Sys tomu in Category 1 l 1 Structures," with regard to allowing piping to be inspected i for final line and grade with eithur tempor ary or pormanent I.. hangers installed. - I The correct implomontation of upper-tior requirements was also queuLioned regarding Quality Control TuvL Proceduru. QCT 4.40, " Balancing.of the HVAC System," (QCI-1.31-2-86) and I Quality Contrul Prucedure WONP4CP 1.55, "Gualu, Firustops, and Cable Coatings," (IN-85-849-001). Upper-tier requirements and InduvLry GLandards had buen cur'rectly ; .] implemented in both instances. 'In the~ case of QCT 4.'40, I j specifically, there ur u no code, utandard or specification .1 r requirements for Quality Contrul involvement.in balancing of IR6 HVAC dyulums. Rugarding QCP 1.55, adoquatu requirements for i inspecting the" boards" can be found in.the attachments Lo this I proceduru. -l 1 Conclusion l f The issue that certain Quality Procedures lacked acceptanco l criteria wau nul verified av facLual (class A). The l procedures reviewed in evaluating this issue had adequate IR6 aucuplance criteria. I b. 3.2.4 Issue - Proceduros used for Quality Inspections have conflicting, unclear, and incomplete accuplance critor ia rusulting in inadequaLu inspection results. (IN-06-266-X10, ~ IN 06-208-02, IN 85-947-006, BfN-86-033-001,;0NP QCP-10.35-), IN-85-993-005, IN-85-380-002, IN-85-259-002, . c IN-85-334-001, 2850162003) (Generic) t ,n w__ J
m o l TVA EMPLOYEE CONCERNS ' REPORT NUM8ER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 t i l PAGE 31 0F 144 l .l ~ I 1 Specific Evaluation 1 1 This issue was evaluated at WBN, SQN, DFN and'BLN. ] 1 i The following documents were reviewed for applicability to the .] issue: BNP-QCP-3.4, " Electrical Cable Preparation (Termination) j 600 Volts or Less and Jumper Installations"; WBNP-QCP-3.06-3, " Inspection of Cablo Termination"; Modification and Addition Instruction (M&AI-7), " Cable Terminations, Splicing, and Repair of Damaged Cables"; QCP-4.10-18, " Arc Strike and Base Metal Defect j Removal"; Ceneral Specification C-53, "ASME Section III and l i Non-ASME Section III. . Bolting Material"; DNP-QCP-6.17, "Selumic Support Installation and Inspection"; NSRS Report IN 85-234-WBN; Standard Practice SQM1, "SQN Plant Maintenance"; j QCII.40 6, " Civil Engineering Tracking UniL"; QCII.40-7, "N3C-912 1 Tracking Program." J Discussion Requirements for clear, conciso, and complete Quality Auvurance/ Quality Control Procedures and Instructions are'definod in Section 17.1.2.4 " Quality Assurance Program implementation" of 1 TVA'u Topical Report. This sucLivn slates in part that, "The ] i Office of Engincoring and the Office of Construction preparo and maintain Quality Assurance Procudurus covering those aspects of the Quality Assurance Program which require written procedure. and well-defined activities." 1 The evaluation of the issue was accomplished through review of applicable implementing procedures at all nuclear sites. 'The i I following are examplos of unclear /doficient acceptance criteria. 1 1 l l
TVA EMPLOYEE CONCERNS REPORT NUM3ER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 32 0F 144 F Review of applicable cable termination and insulation inspection prucedurus at WBN and OLN (IN 86 266 X10) has rovouled that resistance and continuity tests are required, however, they did not specify vilhwr the approvwd mulhud for performing the conLinuity tests or when to perform them. Rwui> Lance Luuling requirwmenLu had been Lranu furrud to a Quality Control Test Procedure and woro adequatoly covered. At BFN, similar circumulanceu exial, AL GQN, procedur au contained Lho requirements necessary to adequately conduct the testing and inspections. Procedures governing the hydros tatic pressure Lesting of instrument lines warw also ruviewwd at all sites (IN-86-288 002) to determine if static head pressure had been taken into consideration during twsLing. IL was found that bufuru lho 1985 revision to General Construction Specification G-29M Section 3.M.9.1 there woro no l ruqui r emwnlu Lo include calculaLiunu for utalic head pr ussuru when deLurmining the paramotors for hydrostatic Lesting at WBN, OFN or SQN. Evaluuliun al OLN hau thuwn Lhal RLU Constructive Test Proceduro 7.6, " Hydrostatic Testing," does require engincoring calculation Lo avoid uver prwusurization when major uluvation [, changos occur. I Requirements governing the removal of baso metal defects (IN-85 947 006), olhwr than are uLrikuu, Nero nul addrussed procedurally until March 1984, when Quality Control Instruction 4.03 1, "Dauw MeLal Owfec t Removal" was iuuuud. In May 1986, the applicable acceptance criteria was added to Quality Control Procedure 4.10-18, " Arc GLrike and Base MeL41 Defect Removal." i w. p m
m \\ TVA EMPLOYEE CONCERNS REPORT NUM8ER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 33 0F 144 i r At DFN (BFN-86-033-001) TVA memorandum (R42 860709.787), issued-July 21, 1986, states that Modification and Addition Instruction, M&AI-23, " Support and Installation of Piping Systems in Category 1 Structures," had unclear and insufficient acceptance criteria. BFN-CAR-86-0120 was issued July 11, 1986,.to identify a conflict between General Construction Specification G-29C and Nuclear Power Procedure N73M2, The QACEG ovaluation disclosed that TVA has addressed procedure deficiencies in the Browns. Ferry Nuclear Perfortnance Plan (BFNPP), Section 2.4, " Procedure Upgrade," page 'f II-35 through II-39. The 8FNPP is a TVA commitment to the NRC to identify procedural deficiencies and the planned corrective l actions. In this case, however, it fails Lo address retroactive evaluation of the quality of any hardware that may be affected by procedures deficienL during, installation. Similar circumstances exist at BLN, SQN, and WDN and within the respective NPPs. TVA's corporale NQAM stales that CAQRs are required whun procedures aro l found to be deficient in technical or QA content. However, like lhe NPPs the NQAM fails to addrevu ovaluation of hardware accepted i to procedures found to have deficient acceptance criteria, BLN Proceduro BNPQCP-6.19 " Bolted Flange Connections," does not fully incorporate the Process Specification G-53, "ASME Section III and non-ASME Section III. Bolting Material." (BNPQCP 10.35-9) G-53 requires heat code traceability, for bolting greater than one inch diameter, for ASME III Code Class 3 und for ASME III Subsection NF bolting material supplied with a certified material test report (CMTR), while BNPQCP 6.19 requires traceability for class 1 and 2 material only. Another example of unclear acceptance criteria can.be found in 1 Modification and Addition Instructions M&AI 4 and 5 in use at WBN 'l (IN 993-005). These procedures required in-process inspection j of terminal crimping operations, but only require craftsmen to l notify inspectors after crimping is complete. A portion of the 1 i ") 1-ll! 3 0 m ______1.___..________J_____________________________._____.__
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_y s s TVA EMPLOYEE CONCERNS REPORT. NUMBER: -80200 SPECIAL PROGRAM REVISION NUM8ER: 6 l PAGE:34 OF 144 issue (IN-85-388-002) states that QCI-1.40-6 Revision 0, " Civil' Enginuoring Tracking System," contains arrors and does not reflect current practice. As a result of QTC, Report IN-85-388-002, Revision Request Number 295 was initiated and incorporated in l Revision 1 of QCI-1.40-6 dated August'5, 1985. Another portion of-Lhe issue states that 'certain procedures signed by TVA and. HS8 1 supervisors are not in accordance with ASME codes (2850162003). No ( t .' Incomplete information helpful in resolving this could.be located. l acceptance criteria or criteria incorrectly implementing upper-tier l requirements, has been evaluated within-this is:ue, 10CFR50 Appendix B and TVAs Nuclear Quality Assurance Manual require a program to review documentation, As required by procedure QCI l'.08 (IN-85-259-002 and.IN-85-334-001), TVA has elected to utilize responsible engineering units to evaluate QA records. Among these ~ evaluations are those-for acceptanco of records' documented to - susperseded procedures that do not meet current requirements and those for which previously existing documentation has been lost. Propur forms exist as attachments to the QCI for documenting such l evaluations. Conclusion t f, The issue that procedures contained unclear, conflicting, or incomplete acceptance criteria was found factual at all four ( sites, This issue prosents a problem for which corrective action has been, or is being, taken as a result of an employee concern-evaluation (class D). L Causos The cause of procedures containing unclear, conflicting or incomplete' acceptance criteria stems from a failure by management lo establish an adequato review process for procedures, specifications,' drawings, and instructions. b.+ .-.r- + +
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I TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 i PAGE 35 0F 144 j l i Corrective Action Electrical Quality Control-WBN performs continuity and resistanco l Lusts af ter ' cable Terminations are completed, which violates QCI 3.06-3. sggy g 6- -p2 uality Assuranc '-W8N e has s Lalud I E35 GniEFbiU lg "The ce blus shall be erminat ermi eg p evi 1 aid'dou n, after continully and in., du 'i' " H on has been concurred.with by QACEG. WBNP-QCP-3.06-3 and DNP QCP 3.33 do not address an approved method of performing continuity verificallun of wlwcLrical cablou. Eluctrical Quality Control-WBN stated, in response to CATD 80:'% -. ~, -. e.T :.0v -; n ii ~m ruv. uu.ovur g-r a ting I '*THIS ITEM COMPETED-- ) phdneu ur un equivalunL mwLb d. cunnwcLi tu.ill be madu t.c uach -1 Inc ividual r and L o$r{f o o to form a complele ci.-U..L !~'...... .uud un the . ~.. _ ~, - ma uuw conductor being tested and using the other load to test all other ] conducLuia god ip v v. iv j ivr vuoLinuicy ia r c r u n a cai r., inis re s pon t.w was coricur b osponse t ) CATD 80204 8Lfh02, Lhat ONP P 3.33 will be r rived clude propor '"0EC concarred. methods t or cabl {tyver Ea n CunuLruction Enginuorinq WGN, in response Lu CATD-80206-WGN-01, t i N a p u Cu ut u Li th s.ta ad pros sure, duo Engineer ir9 - W o ov net Lu wlwvs Ltun'diiiwrunceu durtog hyuruscacic Lastany, ur ou Lud any condition adverse to quality. This response was' accepted by QACEC. Muchanical Engineering SQN and InulrumunluLion Engineering - BFN have been tasked by CATDs[0252-SQN-0)and 802$2-8FN-01 to A lTHIS ITEM COMPLETED DATE: 746-BB 3
q y s 1 I TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 l SPECIAL PROGRAM REVISION NUMBER: 6' PAGE 36 0F 144 evaluate the static head pressure problem at those respective
- sites, The rwspective Enginouring Groups havo replied that a review will be. conducted of " worst case" systems. Should the review' reveal s trusu levels above code allowablev ur a failure, a
CAQR will be written. QACEG has concurred. The existence of duricient procudures and commitments-Lo corrwet I ') them have been identified in the Nuclear Performance Plan, Huwwvur, there are no requirements in place to evaluate the quality l uf hardware accepted to inspection critoria found later to be j duriciwnt. Thu Division of Nuclear Engineering ovaluated the problem in response to CATD_80252-NPS-01. The NQAM, Part I, 1 SucLlun 2.16, "CurrecLivw action, will be ruviuud to requiro a l review for impact on hardwaru duo to identification of documents such au pr ucodure or specifications found Lu be duriciunt in I specifying the inspection / acceptance critoria. DNQA has rosponded with th'w unmw slaLwmwnL in ruplying Lu CATD 30202-W8N-01, Site Enginuaring - BFN has responded to CATO 80202-BFN-04 stating that i Lhw NQAM, Parl I, Swclion 2.16 will bw revised tu addruss { specifically what actions are necessary when deficiencies are found in qualiLy rwlalud procedurvu, Also, GOSP 3.7 will be revised to i implement the requiromonts of the NQAM. This response has been accupled by QACEC, Specification G-53 requires heat codo' traceability for ASME bolting maturial with a nominal diameler greaLor 'than one inch. BNPQCP-6.19, Revision 3, only requires recording heat numbers for clasu 1 and 2 bolling malerial. QCP 6,19 dous nol. incorporate lhe G-53 requirements for class 3 bolting material. Quality Assurance BLN providud the following currective action for CATD 80204-BLN-01: CAQR BLP870365 has boon initiated to DNE to track verificallun of and vulablishmurt wheru deficient, the ASME b 6 .se l l +,,.
I TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 j i PAGE 37 OF 144 requirements for th5 911 projecL; make the necessary corrections to bring all BLN project procedures into complianco with ASME code and l l associated regulatory commitments. QACEG has concurred. l l 1 ot g r 3, v (as add vued' i 308-WGF ) uji ille for the text that follow da I.u w v.. _ - - ^ ^ ' ) MAI-4, Revision 5, and MAI 5, Ruvision 8, failud dress in-process. inspections for lug crimpin ur to the so of raychem heal shrink Lubing. Modifi ns ff GN alud that bulh j M at a QC inspection procedures will 1se ha$1 ho ld po ' Thi t s ilut o since thu first ni bo h proc r au verification signatures that L w.,uy h ut> vr adequato crimping, wiru inserti n, etc. this verification no-lugged Termination-would be tdurud complete and would nul bu accuplablu l l l (CATO 80208-WBN-02) The responso.was accepted by QACEG. l l 3.2.5 Isuuu Nulice of Indications (NOIs) and Maintenance Requusts do not have a proper tracking system. This results in the uriginatur not knowing thu utatuu of Lhu document at any given time. (xx-a5 102-008) (Goneric) Spweific Evaluation This issue was evaluated at WBN, SQN, BFN and DLN The following documents were reviewed for applicability to the issue: NQAM, Part II, section 2.1, " Plant Maintenance"; NQAM, Part III, section 1.1, "Documont Cont.rul"; Standard Practico SQM2, Revision 19 and 22, " Maintenance Management System"; SI-114, _.t g ..a.o ed
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 i PAGE 38 0F 144 l l 1 Section 17.0, Revision 4, " Inservice Inspection Program"; AI9,2, " Maintenance Requests"; TI-50A, "ASME Section XI Pruservice Inspection Program"; BLN Standard Practico 10.2 " Processing and. l ( Scheduling Maintenance Requests." t Discussion t This issuo has been evaluated-at all 'four of TVA's nuclear plants, i At SQN, NOIs are controlled by Surveillance Instruction'SI-114.1 " Inservice Inspection Program" which provides for notification to the issuing oryanizallun of the disposition assigned. MRs are controlled by Standard Practico SQM-2, " Maintenance Management. Syulem " This proceduru requir au Lhw responsible unit Lo-notify the Maintenance Scheduling Unit when changes or cancellations of MRs uceur, Thuru is nu mention of notifying Lho originator of such l changes or cancellations. A review of Technical Instruction TI-50A, "ASME XI Prosorvico l Inspection Program" at WBN and SI4,6 " Inservice InspucLlun Program" I at BFN showed that NOIs are generated by the Nondestructive Examination (NDE) Inspection Section and approved for issuanco by the section representative. Theso documonts state that upon completion of correctivo action, lhw NOE suction repreventaLivu verifies complution and signs'the NOI for closure, Therefore, the NDE Inspection Section is the only group involved with the generation, inupection, and closure of NOIs. AL WBN a review of Administrative Instruction AI 9,2, " Maintenance Requests," did not uhow a re'quirumunt that the originating department be notified of the disposition of an MR, If.the disposition involves inspection of the work by a group other than Lhe originator, the group performing the inspection is responsible 5 6. W 9
j \\ l TVA EMPLOYEE CONCERNS _ REPORT NUMBER: 80200 SpECIAL PROGRAM REVISION NUMBER: 6 PAGE 39 0F 144 for documenting and ~ closing the MRi However, if an MR is I rejected or cancelled at any poinL it shall be markud' " rejected" and the second copy returned to'the originator. AL BFN, MR initiators are also notified prior to cancellation l of an MR, 1 4 At BLN discussions were held.with the Maintenance Super inLundunt and BLN Standard Practice 10;2, " Processing l and Scheduling Maintenance Requests," was reviewed to dularmine if MR initi4 Lor v were riotified of thu MR status. I It was determined that if an MR is denied, it is returned to l Lhu originating department with a jus tification for nul l 1 i performing the work. { Conclusion l AL SQN this issue was found factual and a problem for which i i.or rec Live avlion has buun, or la boing, Lukun au thu rusuit of an uvaluation (class D). 3Landard Pr actico SQM2 duus nul pr ovide MR ur work r equest (WR) status information to the initiating' individual or orgariizallun. i Note: MRs aro being replaced by WRs at SQN. i AL WDN, OFN, and BLN a uimilar problum duas not oxis t sinco applicable implementing proceduros requiro copies of rejected I ur cancellud MRs La be roLurned to the originatur and NOIu dlWdys stay Within the inservice /preservice inspection group. Completed MRu are utaLuuud and bucumu pur manurit plant j documents available for review upon request. t E a 1
TVA EMPLOVEE CONCERNS REPORT WUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 40 0F 144 Causos F The cause of Maintenance Requests not having a proper Lracking syulam is that pr ocudur w SQM2 does nul provide MR or j WR status information to the originator. Corructive Action l The SQN Site Director responded to CATD 80202 C -01 on I OcLuber 20, 1986, and commillud to ruvis esM2 L incorporate provisions for notifying the orig' i section rejected i or caricelled WRu. SQM2, R tu ilis t Itu Number 7, da ted February 10, 41 u t-ccording to section F. (ki e t < n,C' s an bu s s holl6-Np' disposi no s it states " cancelled WR, arg Q ru a ai i discardud." To unhancu the so s WR h s anWa F dback to the originator, thu origiiaLing Li will be nulified uI t.he ruat,un WRs aru ruject ncelled." This revision provides justification au l.u why a WR iu cancellud and unablub Lho uriginator tu challenge inappropriate cancellation or rejections. QACEG has curicurr ud. 3.2.6 Issue - Excessive and uncontrolled procedural revisions and drawing r evisions havu caused confusion for the craft. (SQP-86-009-XO3, IN-85-171-001, IN-8 5-4 4 5- 008, IN 86 307-001, QCP 10.35-8-261, IN-85-903-001, QCP-10.35-8-34, QCP 10.35-8-30, IN-85 -596 004, QCP 10.35-8-27) (Generic) l i l I f
.e .a. TVA EMPLOYEE' CONCERNS' REPORT NUMBER: 80200-SPECIAL PROGRAM i REVISION NUMBER: 6 1 PAGE 41 0F.144 Specific Evaluation . l [ This issuu was evalualud at WBN,. SQN, and 8LN l l The following documents were reviewed for applicability to the lusue: AI-4, " Preparation. Ruview, Approval,'and Usu of Plant Instructions"; NSRS Report I-85-452-WBN; TVA Quality-Assurance Program Plan (QAPP); Series 3CA0039-00, " Notes for Field Fabrication and. Installation of Pipe Supports in Calugory I S truc tures. " 4 Discussion ) Appendix 0 to 10CFR50 requires that documents af fecting ) l quality, including changeu lherulo, be controlled Lu onnuru they are reviewed for adoquacy, approved for rulcaso by authoriaud peruunnel, und diul,ribulud Lo, and used al, thu. lucation whero the activity is performed. 'Ihis QACEG evaluation, through review of induulry vt.andards, regulatory. requirements, design documents, and upper. tier documents, did nul idenLify any limit,allons av Lo thu numbur of timus a procedure can be revised. Evaluation of this issue includud review uf numerous procedures and instructions at WON, SQN and DLN. Proceduro revisions were accomplished when required to implement improved industry standards, NRC regulations, design requirements, and upper-Lier documunL changes including clarifications and correction of typographical' orrors as well au managemenL organizational changes. Procedural ruvisluns were and are accomplished within the confines of accepted and approved, s landard u, policies, programs, and procedures.
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_y-t 4 TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM. REVISION NUM8ER: 6 PAGE 42 OF 144 Evaluation of this issue included review of the " Mechanical-p Hanger Orawing General NoLus,'" 47A050 Series and discussions l with~ personnel-involved with hanger inspection and the Department of Nuclear Construc tion (DNC). ONC slated that [ revisions to general drawing notes are controlled by Field Changw RequesLu which muut be generated and approved by Engineering. I QACEG's ovaluation consisted of a review of hanger specification nolus, lioplementing procedurus regarding j commitments for hanger support installation / inspection and requirumenLu for dusign document changus. Also, inturviuws were held with cognizant personnai in'the Hanger Engineering l 1 Unit (HEU), Hanger Quality ConLrol (HQC), and Division of Nuclear Engineering (DNE) BLN. Revisions of the documunts ruviuwud woru, in some casus', 1 frequent, however, discussions of the various changes with thw HEU Group Lwadur, and a ONE BLN site support engineur, revealed that the changes would'not require a reinspection of past installations. The DNE site engineur utaLod thal Construction Specification changos, resulting from Revision i Requwulu by Construction or Specification Revision NoLices by J 1 DNE, were used for resolving conflicts of interpretation, I oditorial reviuions, or changes to lesu stringunt Lulerancus. \\. With proper justification, none of those situations would r uquir e reinupucLion of pas t support ins tallations. Hanger specification notes contained in drawing series I i 3Co0059-00 " Notes for Fluid Fabrication and Installation of-l Pipe Supports in Category I Structures" were also reviewed with the HEU Group Leader. These notes changed frequently throughout the period of support installation beginning 'in ,e i t i L.
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM j REVISION NUMBER: 6-PAGE 43 OF 144 late 1977. Note changes / additions make reference to a rield Change Request (FCR) number. These FCRs aru approved by DNE 1 subsequent to tne completion and documentation of design activities necessary Lo justify and/or substantiate the change. This is in accordance'with instructions in Quality Assurance Procedure ONC-QAP 3.1 " Field Change Request," ] Revision 10. Ouring the discussion concerning specification changes,; the HEU Croup Loader identified two situations where nulu additions to drawings 3GA0059-00-048 and 3GA0059-00-18 caused i paul installation Lu be in quusLion. However, Nonconforming I Condition Reports'(NCR) 4641 and 4815 woro issued to document ) the pouvibility that past inulallations may not have buon in accordance with the added criteria. Another specification change which could pusuibly juopardieu lhe validily' uf paul installations was identified during an interview with the HQC' uuperviuur and an inspucLurs Thu inspector 9talud that load point location dimensions of support installations, as detailed in 1.he Lulurance nuluu un drawing 3CA059 00-06A beforo October 24, 1985, would be rejectable since the Lulerances un this drawing are muru stringunt than Lho Lolerancos used for inspection. On October 24, 1985, noto I.15.A for " Interior Angular Bracing Tulerancus,"'was added to Lhe above noted drawing. Before'this dato, load point locaLion dimensions X ur X2 (X or X etc.) as I g dupicLwd un Lhis drawing were inspeclud using Lhu Lulurances specified for "kneebraces" - 3GA0059-00-048, Noto I.9.B.1 and 2, 1 1/2 inch for Crinnell Drawings and &l/2 inch, -1/4 inch i for TVA drawings. These tolerances are loss stringent than i bulb Lhe originally refurwncud Lulurance of AGME Suction III, Subsection NA, Appendix K and the present reference to noto m. 9 sr __._________________m--
a TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 44 OF 144 t I.1 of 3GA0059-00-01, which was added by FCR H-5500. This condition had not been documented on an NCR or a Condition Adverse to Quality Report. No instances of QC unawareness of general drawing notes could be found. ) As a side issue during the investigation of this concern, it [ was found that BLN HQC was not complying with a note on the Grinnell hanger detail drawings. All Grinnell hanger l drawings have a noLe which states that structural member length (linear dimensions) tolorances are to be in accordance with ASME Gection III, Gubsuction NA, Appendix K.
- However, BLN HQC has inspected Grinnell supports using the loss v Lringent Luleraticus iti General Construction Specification G-43, Paragraph 2.7.2.1, Revision 9.
Concluulon The evaluation determined that the portion of the issuo dealing with excessive procudur al revisions was not factual. The portion of the issue concerning drawing revisions causing l confusion for the craft was found to be factual arid i identifies a problom, but corrective action for the problem j was initialed (NCRs 4641 urid 4015) before the amployuu concerns evaluation of Lhe issue was undertaken (Class C). I Although the abovu acLion had buen initialud, another change 1 s. in the drawing notes series 3GA0059-00, identified a problem 1 not addrussed in the above nolud NCRs and no corroclivu action had been identified or implemented. l l Causes The cause of the problem identified in this issue is that drawing rioles were not being adhered to during installation 1 and subsequent inspection of hanger supports. I [..
v-e I i e. 3 i TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM' i REVISION NUMBER: 6 l PAGE 45 OF 144 j Corrective Action Corrective Action had been addressed by the issuance of NCRs 4641 and 4815. Although the abouw action had been initiated, a change in the specification note 3GA0059-00 Serios idenLified another problem. CATO 80502-8LN-01 was issued Lu ONQA-OLN to identify the possibility that load point location dimensions of support installations before October 24, 1985, would be rejectable since the toleraneco added to sheet 06A of General Nulo, drawing 3CA0059-00 are more stringent than Lhc tolerancos used for inspoetion. DNQA-OLN responded by issuing CAQR BLF 870075 in ut.curdancu with NEP 9,1. This CAQR will be used to track the problem to completion. QACEG 1 has concurted. In addiLion, as a r e sul t, o f a 311.0 t.uncer n, i t CATD 80502-BLN 02 was issued to DLN HQC for not complying j e n av - n of go wral nu .J 9 3C Sg- - 12, 10 87, FCR H-I141 was erfb 6.,,.i. --- -! C q ACEG has ^ ' ^ concurred. 3.2.7 Issue - Supplemental inspection criteria utilized by J inupucturu arw nol documenLud un t.huir ruports. Therefore, the acceptability of the oquipment l inupee Lud cunnul bu dul. ermined. (IN-85-052+004) (Generic) Spocific Evaluation i This issue was evaluated at WBN, DLN and SQN 4 _.___.__-_____-__m_
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80300 SPECIAL PROGRAM REVISION NUMBER:- 6 PAGE 46 0F 144 I i The following documents' woro reviewed for applicability to the issuu: WBN-QCI 1.08, " Quality Assurance records; BNPQCP-6,17, " Seismic Support Installation and Inspection; W8N-QCP-4.23-8, " Support Final Inspec tion; General Drawmg i Notes, 47A050, 3GD0053-OO, 3GB0058-00. and 3G80059-00; j M&AI-11. " Fabrication Installation, arid Documentation of j Supports, piping Systems, and Structures Attached to Seismic l ~ 1 i Category I Structures; Special MainLunance Ins truction, l -SMI-1-317-24, " Pipe support Enhancement-Inspection, EDS luomwLric drawings for inside containment and supports identified and inaccessible". i l l l Discussions wwre hwld wil.h cognizant QA and QC pursonnel'al f all throu sites regarding supplemental acceptance criteria riuL documentwd un inspecLion repor Lu. Discussion Appendix 8 to 10CFR50, Critorion XVII states in'part: "InspucLlon and t.est recordu hall, as a minimum, idontify the irispector or data recorder, the type of observation, the l results, the acceptability, and the action Laken in I connection with any deficiencies noted." I QCI-1,08, Ruvision 10, dated July 13, 1984, " Quality Assurance Records," states in Sectione 6.1.2 and 6.1,2,1,12 "The responulble ungineer or irispwcLor enuures that rucord preparation includes the following requirements Nuncoriformance Reports (NCRu), Fiuld Change Ruquusts (FCRs), variarices, addenda, deviations, On-Scone Coordinators (OSCs), I wlc,, Lhal aller inupucLlun accepLance criteria aru referenced on the documents." ,yy
v j TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 ~ SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 47 0F 144 I Implementing procedures require the responsible ~ engineer or inspector lo unsuru that rwcords includu reference to any-document that may alter inspection acceptance critoria. Review uf inspwclion ruports and discussions with QA/QC personnel revealed that the supplemental inspection criteria j in the general drawing notus aru not being referencud on reports, and therefore, a third party could not determino what crituria was usud by QC to accupt Lho installation. Increased tolerances and supplemental information contained 'in the gunural drawing notes allow deviations from the configuration on the control drawing.and should be referenced un thu inupacLion rupur@. At WBN and DLN, reviews of inspection roports and discussions I wil.h QC puruunnwl revealdd that supplemunLal criLuriu, within IR6 the general drawing notos, are not being referencud on repor Lu. By not documunling' t.hw. uuo of thu 47A050 (WBN), and ] 3C80059 (BLN)-series General Drawing Notes, for supplomontal acewplance criteria un inupucLion reporlu, the accuplability 1 1 of hangur installations can not be dotormined. ) i Thw Enginuuring Cuncwrn Evaluation Group invoutigatud a similar issue at Sequoyah which resulted in a walkdown to i verify 1. hat au buill configurallon mueLu design criteria. This walkdown will satisfy any questions of hanger acewplability within this issuu. Cunclusion The issue that QC inspectors do not document supplomontal accuplancu cril.wria for hanger insLallaLiuns on-Lhuir inspuction reports has been found factual and prosents a problem for which currecLive action is being takun as a I result of the investigation (class D). By not documenting. A s an g u___________
TVA EMPLOYEE CONCERNS' REPORT NUMBER: 80200 SPECIAL.PROGRM9 REVISION NUMBER: 6 PAGE 48 OF 144 ..r' the use of the 47A050 and 3GB0059 series general drawing notes I e for -supplemental acceptance cr iluria' on inspuellori r eports, IR6 7 ) Lhe.use of appropriate acceptance' hanger-installationferiteria i canno t be. de ter mined. I Causes .i The cause of supplemental inspection criteria utilized by l InupwcLors nuL being documenLud on their reports is duo to I failure to follow procedures. The criteria was there but was not udhwred. Lo. Corroctive Action l. WBN ENG/QA has issued SCR WBN CEB 8531 R1 to track problems idunlified by CATO 80201-W8N 02. BLN ENG/QA has issued.0LF l 870126_ to track the problem identified by CATD 80201-BLN-02. l Thusu CATDs wurw wriLLen lo identify Lhat 470050 and 3C80059 IR6 suries general drawing notes, used by QC inspectors for i uupplemwnt.al acewplance crit.oria, are not being documunLud on i the inspection reports. At SQN a walkdown to verify as-built configuration is presenLly on%joing to verify hanger f acceptability. .i f 3.2.8 Issuo ' Proceduros may have been violated when no meg / ohm Luulu were performed un' low volLage cable and wedgu l bolts were installed through robar. (IN-86-252-001, } BNP QCP 10.35 19) (Cunwric) l Specific Evaluation This issue was evaluated at WBN and BLN. i L l l l
m TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 i PAGE 49 0F 144 H The following documents.were reviewed for applicability. to. the' issue: General Cons truction Specification C-32, "Bult Anchors set in Hardened Concrete"; DNP-QCP-2.8, " Bolt' Anchors set in Hardened Concrete"; and QCP-3.06-3, " Inspection of l Cable Terminations." In addition discussions wore held with 1 4 the OLN Auslu tant Plant' Manager,- QA/QC and QuallLy Engineering Personnel at BLN and WBN, and the DLN Superintendent of Nuclear Power Plant MainLenancu. l Discussion o ) l . A portion of the issue is that,'for low voltage cabic, no ] mog/vhm Lwat lu.being pwrformed. The only Luul purformud is a " talk out" for continuity. Review of.Gonoral Specification C38, Rwvision 8, "Inulalling Insulalud Cable Lu 15KV Inclusive," and QCP-3.06-3, " Inspection of Cable -l Termination," Reviulun-10, ruvualud that Lhuro is nu j requirement for moggering low voltage cable. Thoro is no ' I prouwdure or vlucLrical code requirement Lu perform Lhis' Lost IR6 un low voltago cable, t Investigation into Lhe rust of the issue, ruvuulud that, in questioning the installation of wedge anchors, the concerned individual stated be fult it was possible that pipe sluovou l may not have boon installod'for wedge bolts which were uubu LiLuLwd for. sulfWrilling anchors when Lhe se1f-drilling. I anch' ors encountered reinforcing steel during installation. IR6 l ONP-QCP.2.8 " Boll onchuru Sul in Hardened Concrelu," Ruvision 3, December 18, 1978, allowed substituting wedge anchors for expanulon uhw11 anchuru (uulf drilling anchors) If reinforcing steel was encountered during installation of the uulf-drilling anchora, ~ ollachment E Lo QCP 2.8 "Proceduru _____m__._-__.__ _______m._.-_-__-___._.--
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: .6 PAGE 50 0F.144 (' [ .) for Replacing Expansion Shell Anchors with Equal Size Wedge t-Bolt Anchors," required a pipe sleeve Lo.be installed in the hole drilled by the self-drilling' anchor since that type of ) anchor has a. laryer out. side diameter than the replacement wedge anchor. Revision 19, May 8, 1986, of QCP 2.8, provided on Attachment G, an aLLribule for QC verification that the q l { pipe sleeve was installed. 'QACEG verified that General 1 i ConsLeuction Specification C-32,. Appendix E, has identical f requirements to those contained in Attachment E of BNP-QCP-2.8. 1 l l Additionally, the discussions revealed th'at three installations out of a LoLal of 24 had buen disassembled and reinspected. For.the three assemblies that were inspected, Lhe required pipe uluevu had buen installud, I l l '] Conclusion l l The issue was found not factual (Class A). I t l 3.2.9 Isuue The procedur e describing the allowable deviations from the specified dry film thickness (DFT) is I someLimes used incorrectly. QCP 2.12, Attachment A has resulted in different interpretations of the i Acceptance Criteria. (IN-85-511-004) (Site spucific - WBN) t I Specific Evaluation t This issue was evaluated at WBN, t \\- ~
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in
l j TVA EMPLOYEE CONCERNS REPORT NUMBER:.;80200 SPECIAL PROGRAM REVISION NUMBER: 6 I PAGE 51 0F 144 j The following; documents were reviewed for applicability to. the issue: Construction Specification G-55,." Surface Preparation, Application, and Inspection of Protective i Coatings Nuclear Plants";. Standard Operating Proceduros (SOP)-2,1, " Protective-Coatings - Inspections"; QCP 2;12, "ProLuctive Coatings Inspections"; and NCR 6850. In 1 addition, discussions were held with-a; Civil QA Supervisor -) and Inspector and Civil; Design, and Construction Engineurs. I Diccussion ~ l WBNP SOP-21, Revision 0, August 15, 1983,-- and Revision 1,- September 17, 1985, is utilleed for Service ' Level II coatings. -Thoso' coatings provido. decontamination'and i corrosion control for uurfacus located ouluide -Lho primary-' i containment boundary. Failure of.the coating system in thoso areau could impair but noL provunt, normal operation 'of the facility. Service Lovel II areas are nonsafely.rolated and do not require quality assurance documentation. InspucLions are the responsibility of the Civil Engineering Unit.(CCU) and are per formed on a Surveillance Basis. QCP 2.12, Revision 12, is utilized by Quality Control personnel for Service Level I Coalirs Inspections. Thosu coatings are located within the Primary Containment Doundary and are safely related. NCR 6850, Revision 0, was initialud, by CEU on May 27, 1986,'to identify that Revision 4 to ^ Ceneral ConuLrucLion Specification C 55 had not buen incorporated in WBN-QCP-2,12, Rovisions 11 and 12. On OcLober 15, 1986, Deuign Engineering supplemented this NCR with a three pago memorandum (R1MS 026 061015 017)- identifying "adJiLional items Lhat should bu ruvived to bring the QCP 2.12 into agreement with 0-55." ..y . l
TVA' EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 i PAGE 52 OF 144 The last item on page two of this memorandum addressed p-Attachment A, page 2 of. 3 (allowable deviations from l specified Dry Film Thickness) to QCP 2.12, Revision 12. Prvposed acLlun vlates: "DeleLel. This chart is not needed l and has caused many problems by its improper use." The criLeria in Attachment A to QCP 2,12 for Service Level.I Coating Inspection are' identical to the Service Level II t Criteria contained in Attachment A Lo 30P-21. Page one of ( Attachment A to. SOP-21 and QCP 2.12 provide inspection ) \\ . acceptance criteria (specified DFT) for coating systems. Page two is for deviations only. Utilization of page two by inupactora has caused confusion. QACEG discussions held with Design Engineering, Civil Engineering, and Quality Control peruonnel have confirmed there are dif ferent inLurprulations over the use of WBN-SOP-21, Attachment A " Allowable l Devi... ins from Specified Dry Film Thickness (Mils)." Conclusion l l l This issue'is factual and identifies a problem for which corrective action has been, or is being, Lakun as a result of an employee concerns evaluation-(Class D). Different interprelaLionu do exist among Design Enginuaring, Civil i Engineering and Quality Control personnel with regards to I i specified dry film thickneus criteria. TVA has documented i this on NCR 6850, however no evidence exists that an evaluation was conducted by TVA lo dulurmine thu adequacy of Lhe DFT inspections performed to date. Causes The cause for the issue is inadequate procedure review. The acceptance criLuria iu conflicting and should have boun l b l
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 53 0F 144 identified during the proceduro acceptance review. Also, the i fact that no ovaluaLion was conducted to assure adequacy of j inspections to date, is the result of poor implementation of l 1 Lhe correcLive action /prevenLive acLlon program. Corrective Action NCR 6850, Revision 0, was issued by TVA on October 15, 1986. This NCR identified the imorocor use of Allachmont A to y ^ ' E -c-f Nuclear Power QCP-2 L vi o (ONP)! p tB" O MH 8 thb J u$ nl A lo { {s.,t proc uro SO sion 1 ric c acceptanco crituria as QCP-- .1 , iievtuton 12, uy ueluting pt4ye 4 af both I attachment A's. This response to CATD 80218-WON-01 has been IR6 concurred with by QACEC. A vocondary problem exists becauso uf the different interpretations existing among Design Engineering, Civil Enginuwring, and Qualil" .Mirsonnul ( wii.h recard" m iiicd dr criteria 1 .q g All %h n br 850, r o 'r - Wsts that an oval tprl d 4 to e to_dc termino evid e j Lhe, duquacy fT i" pe ri o rnu"i .. Z Thu .u. a ONP rksooned ' ' _. mu results of an ovaluation show that no hardware problem exiuLu. Thiu reply Lo CATD 80218-WDN-02 has been concurred with, i 3.2.10 Issue - Electrical inspectors get by only with the help of l procedurus and bucause of their inexpuriunce l sometimes accepted unevenly bent conduit and conduit I having too many wxposed thruads at the joints. (00-85-005-002) (site specific - SQN) .I -___.-__.__--___--__--_.--___--_-__._--__-J
m '~ TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 54 0F 144 I Specific Evaluation i This issue was evaluated at SQN. The following documents were reviewed for applicability to the issue: NSRS Report I-85-968-SQN; Electrical Design f Standard DS-E13,1.7; General Construction Specification G40, "InsLalling Electrical Conduit SyuLeiiis and Conduit.Boxus:" SQN Nuclear Power Inspection Instruction Number 26, " Exposed I ' Conduit and Conduit Box Inspection;" Franklin Rusuarch Technical Evaluation Report TER-C5506-649. j Discussion There are two aspects of the first part of the issue. One dualu with using procedures during the inupection process. The other deals with the use of these procedures by inexperienced inspecLoru. In ovaluating the first aspect of the issue, QACEC reviewed Appendix 0 to 10CFR50 which states in critoria II that the Quality Auuurancu Program "shall be documented by written policios, procedures, or instructions and uhail be carried out... in accordance with those policios, ) procedures, or instruction." To comply with this requirement, Quality Control inspectors throughout thu i industry are trained in the use of procedures. Also, an \\~ accepted pracLice within the induvLry is for the inspector to have a copy of the procedure in his possession during the. inspection, i l For the second portion of this issuo NSRS Report I-85 968 SQN, Sequoyah Nuclear Power Inspuction Instruction Number 26, " Exposed Conduit and Conduit Box Inspection," and TVA General Cons tr uction Specification C-40, Installing .L
.a \\ i TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 l SPECIAL PROGRAM REVISION NUMBER: 6 i PAGE 55 0F 144 Electrical Conduit Systems and Conduit'Boros" were reviewed for requiremenLu and applicability. Through this review it 1 has been determined that inspectors were not required to inspect conduil runs for exposed threads or for unevenly bunt conduit. Instead, the requirements for bending conduit are found within Electrical Design Standards and those for 1 exposed threads are in the Construction Specification, both requirements are the-responsibility of the craftsman. 1 Conclusion The issue of inspectors accepting unevonly bent conduit and conduit joints with exposed throadu, is factual and presunts a problem for which corrective action has been, or is being l Laken as a result of an evaluation (class 0). Il should be noted that inspectors were not required to specifically inspucl for' unovun bends or exposed threads. However, thosu conditions may have existed in conduit systems accepted by j Quality Control. Because of thu lack of. inspection I l requirements to verify installation, a review by the l Department of Nuclear Enginouring (ONE) is required to determine if conduit installations are acceptable. Causes The cause is that the procedures governing inspection did not require inspection for the specific altributes identified in the issue. 1 Corrective Action l DNE has completed their evaluation and concluded that "no correcLive action is required to inupact Lho prusuntly installed conduit system for inappropriate running threads or m 9 O l
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 1 SPECIAL PROGRAM l REVISION NUMBER: 6 j 1 PAGE 56 0F 144 I i ] unevenly field bent conduit". Justific- ' pro ided and j addressed in the acLi r 870130 8 1), t dat-rebr ry av r-A tined t at this L(harm con i L , w ill, h ve r n c e j (- 9 1 conf 'sion, I ' Proc a ton of ) s j Condt ' t and - i io wtil be _ revised to provide 1 I inspe ion requirements for conduit bending and conduit running threadu. This response to CATO 80202-SQN-02 has been .1 [ concurred with. l ) 3.3 Incomplete / Inadequate Inspections j I 3.3.1 Issuo - Inadequate Cable Pulling Program. Fundament.al ] problems wit.h establishing, implementing and d unforcing program requirements for cable pulling. ] I (IN-86-254-006, IN-86-212-002, IN-86-266-XO9) l (Generic) \\ Specific Evaluation ) i This issue was ovaluated at WBN, SQN, DFN and DLN. k l The fullvwing documents were reviouwd for applicability to the issue: WBN-QCP 3.05, Revision 28, " Inspection of Cablo 1 ) InslallaLionu"; Construction Specification C-38 Ruviuiun 6, " Installing Insulated Cable up to 15kv"; Quality Assurance oudit. Repurt W8 E 79-05; MINI INPO report dalud Fubruary 14, 1985. Discussions woro hold with Electrical Quality Cont.rol l Gupervivors, Qualit.y Control inupactors, Eluct.rical I l f Engineering Unit Supervisors, and electrical engineers from all four uit.au. j l I l L, L___.. _ _ _ _ _ _. _ _ _ _. _ -
v TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NbHBER: 6 PAGE 57 0F 144 l Discussion At WBN, review of QCP-3.05 " Installation, Inspection and l Testing of Insulated Control, Signal, and Power Cables" indicated that inspections of cable pulls were required to be - l l performed by engineers / inspectors. ' Excerpts from that QCP for different time frames are provided below: QCP.3.5, Revision 7, January 29, 1979,' paragraph 6.1.11, states in part, "a responsible engineer shall be assigned to each pulling crew Lo witneuu the cable installation for the purpose of verifying that the maximum pull tension was not exceeded, minimum bund radiuu was not violated and all aspects of the pulling operation are satisfactory. Contrary Lu Lhis requirement, QA Audit Report WO E-79 0-0, February 26, 1979, through March 9, 1979, documented the observation that cableu 1-4V G7 30438, 1-4V-67-30208, 1-4V-67-30518, 1-4PL-215-49858 and 0-SPP-02-5910 woro pulled without the presunce of a responsible unginuar. The auditor observed six cablo pulls and only one had an enginoce present. QCP 3.05, Revision 21, Suplember 10, 1984, paragr aph 6.1.1, states in part, "The installation of cable requires in-proceus inspecLion ruquiring the presence of an inspector throughout the installation process. An inspector is assigned to each crww t.o inspect and ' document cable pull activiLios." Contrary to this requirement, finding Q.P.3.1 of the Mini INPO Internal Audll concluded thuru had been.a " failure of electrical inspectors to verify proper attributos during cable pulling operations." t 'e s
g TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 50.0F 144 t^ In addition, QA Audit Report WB-E-81-03, July 27, 1981, e documented the observation of cable pulling operations of . l cables 1-2PK-3-1305-E, 1-2PM-3-1445-E, 1-2PM-3-31563-E and i 1 2PM 3 1685 E. During the course of the audit, it was discovered that the procedure requirements for installing cab 1ws had bewn deleted from QCP 3.05 in Revision 12, which 1 Was issued June 24, 1981. The procedure for installing cable i was Lo be placed in QCI -3.05, Revision 0, which had not buen f issued; therefore, all cables pulled after June 24, 1981, had buen ins talled without a procedure. Slup Work Order SW-12 was initiated by the site Quality Assurance Unit on July 17, 1981. NCR 3479R was issued July 18, 1981, by the EEU to document that all cablev installud betwoun June 24, 1981, and July 17, 1981, were installed without a procedure. The stop work ( l order wau lif ted un July 19, 1981, after the project issued QCP-3.5 Revision 13, which included cable installation requiremenLv. 1 NSRS Report I-86-06-WBN documented the investigation of an wmployew concern regarding the aduquacy of cable inspection l at WBN. The investigation was conducted to determine if the cablw inupecLwd was pulled through approvwd design roulos, or, if the approved route was closed, was an alternate route selected and approved by enginuuring before pulling the cablu. The NSRS investigation found that there were significant and fundamental problems with establishing, implementing, and enforcing the program requirements for cable activities. It was decided that inadequale or incomplete design standards [, and construction specifications, and a general failure to responsibly resolve the identifiud problems had resulted in ( L-h m_
v c {. J TVA EMPLOYEE' CONCERNS . REPORT NUMBER: '80200 SPECIAL PROGRAM REVISION NUMBER: 6 j PAGE 59 OF 144 t l 1 ' an indeterminate cable installation program at WBN. It was concluded'by NSRS that the exislunce of.Lhese conditions-would not provide assurance that the cable system would be i capable-of performing its design' function dur ing the life uf the plant.for all postulated events and conditions; 'The main I areas of.; inadequacy citud' by NSRS were cable bend radius j P requirements and cableLpull tension requirements. The NSRS inves tigation' did not subs tantiate 'thu ' mor e specific' concern - of the employee, that cablol routing was not adequately ') 1 in s pec Lwd '. ~ NSRS' Report I-85-466-WBN documented the investigation at WBN: uf an employwu'.cuncurn regarding an apparent lack of 'covurage of safety-related cable pulls by Electrical QC. inspectors. The inves tigation did not subulantiale the concurn. i AL'SQN, Inspection Instruction SNP 11-20 " Cable pulling I Inspuction" was. reviewed to dut.urmino wholhur adequatu .l instructions and acceptanco criteria were provided for 'l safoty-rulalud cable-pulling inupuc tions. Additionally, Modifications and Additions Instruction M&AI-4 " Installation of Control, Power, and Gignal Cablou" was ruviuwod for - current requirements. Cognizant individuals from EQC who: l performed cable-pulling inspucLions al SQN us uurly av 1977 were interviewed. They stated that, whilo an inspector could; not always be al all pointu of 'a pull at all times, there had been no lack of coverage on "Q" cable pulls'. Inspectors were noLifiwd beforu the pull, and thw pulling upurations wuru - inspected and documented. AL DFN, M&AI-13 " Control, Power, and Signal Cablo, unit 1, 2, 3" was ruviewod.Lu es tablish inspection' ruquiremunt.s for cable pulling in.the 1978 time period. Paragraph 5.7 statos: _m_. m_
v u TVA EMPLOYEE CONCERNS ' REPORT NUM8ER; -00200 SPECIAL PROGRAM REVISION NUMBER: 6' .PAGE 60 0F 144 Tho quality control inspector shall be responsible for tho 7 following activilius: l
- a. Verification of all Class lE cable routos..
\\
- b. Verification of all Class IE and CSSC cable terminations,
i F l j l
- c. Inspection of all cable splices mado por the provisions of l
I this procedure,
- d. Perform other. inspections and tests as assigned in the workplan.
Paragraph 6.2.3.1.b states: ) " Observe the cable pull to ensure that the cablo is routed I l properly and is not visually damaged." l Before 1906, inspect.iun pursunnel were not requirud to witnoss. removal of cablo from cablo' reels, Lo monitor pull Lunuion, or lo inspect for bead radius violations. General Construction Specification No. G-38, " Installing Insulated Cablus Rated Up to 15,000 Volls," Revision 7, January 15, j 1986, included requirements for future modifications at BFN. To incorporate t.he cable installation requirements of C-38 for installing cable in raceways, M&AI-44, " Cable Pulling For InsulaLod Cablev Rated Up Lo 15,000 Volts - Units 1, 2, 3," t Revision 0, September 9, 1986, was issued. M&oI 44, Paragraph S.3 establishes that the QC Inspector is i responsible for performing inspections to the acceptanco criteria in the invLruction. AllachmunLu 1 through 4 of the M&AI establish the cable pulling criteria and provide data L1 ___--m_--___.
r r s TVA. EMPLOYEE CONCERNS REPORT NUM8ER: 80200 i SPECIAL PROGRAM i REVISION NUM8ER: 6 PAGE 61 0F 144 1 sheets for verification and sign-off. The inspection attributes include second party (QC) verification for cable identification, pull force monitoring, routing, spacing, 1 cable lubricant, ' and bend radii, as a minimwn. I a At BLN, BNP-QCP 3.34 " Electrical Cablo Installation (Pulling)" ~ was reviewed to detennine if adequate instructions and I acceptance criteria were given for safety-related cable l pulling activities. Additionally, audit reports from EQC, TVA DNQA, and the NRC were reviewed. Cognizant personnel from EQC and EEU were interviewed. An internal INPO review Ludm performed an audit between February 20 and March 2, 1984, which resulted in a few findings in the electrical area. On June 29, 1984, a response to the findings was addressed in a i final rupurt from W. R. Brown (RIMS EDC 84 0629-702). Finding CC.S.1 stated some areas of inspections were i inaduquale. The response indiciled that addiLivnal training 1 had been given to all Craft personnel and Quality Control Inspectors involved in cable pulling activities. "Thu training is being provided to all craftsmen, emphasizing the - I necesuity lo adequately proLuct installed equipment from being damaged. Management oversight and surveillance will be ~ focused un and increasud in. these areas until confidence is gained that requirements are being met. Reinspection activilieu in the electrical areas have buon increased with more participation by supervisory personnel to ensure the integrily of the inspecLion function. Inspoetivn urrors aro l being documented and corrected. Specific feedback is provided Lu lhe inspector in error, and foudback regarding the error is provided to the entire inspection group." Two follvw-up internal audits (6-19-84-JLL-0 and 8-16-84-DAC-3) were performed and no deficienclos wore observed. The NRC performed an audit from February 10 Lhrough 13, 1986. (#50-438/06-01; 50-439/86-01 RIMS A0286-36706) No violations or duviations were idenLified. e
u s TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM i REVISION NUMBER: 6 PAGE 62 OF 144 i I Conclusion -l c~ ~\\ As a result of the investigation which included discussion j with individuals involved with electrical inspection and r i review of the applicable documents the issue was found factual and presents a problem for which corrective action has been, or is being, taken as_a result of an employee concerna evaluation (Class D). Cables were pulled at W8N f without a responsible engineer present during the pull, _ The inuue was found to be factual at OLN with corrective action implemented. The issue was not factual at SQN and BFN. I Causes 'I The cause of inadequate cable pulling program stems from failure to follow established procedural requirements for witnessing cable pulls. There are also inadoquato design standards and construction specifications, and, at WBN, a general' failure by management to responsibly resolvo identifiud problems, resulting in an induturminato cablo installation program. I 02rrects;g Action i Construction Engineering was assigned responsibility for corrective action for CATO 80213-WON-01 which documents that cables were pulled without a responsible engineer present, The correcLive action plan indicates that of the five cables ] l addressed, one was completely repulled; three were reworked j buL not replacud; the fifLh was not replacud or ruworked but tested and has been in service for several years. Additionally, TVA at WBN has recognieud that there is a possible problem with all cables concerning bond radiu's and f i side wall pressure. This condition is documented on NCRs 1 i i lL. m_____-_.m. ---s- - - - - - - - - - - - - - - - " - ^ - - - - - -
l l TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 1 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 63 0F 144 I 6295, W-290-P and 6270. NCRs 6295 and W-290-P' identified bend radius problems dL specific points but DNE expanded them 1 to include cable bend radius in all plant areas and NCR 6270 addresses cable side wall pressure. DNE is curruntly working i on the disposition of the problems. QA Audit Report W8 E-79-05 recommended corrective action to ensure that each cabl6 pulling crew was assigned a responsible engineer before i Lhe pull was started and to instruct craf t personnel to notify the Electrical Engineering Unit when a pull was anticipated. CorrecLive actions Laken as rusult of the NSRS investigation include issuing Electrical Action Plans 24, j " Cable Bund Radius," and 25, '" Cable Pull Tunzion," These plans will resolve adoquacy of dispositions for identified cable bend radius problems and adequacy of cablo program for cable pulling activities, i At BLN the inLurnal INPO-Reviuw Team did an audiL (BLN 84 0806302) between February 20 and March 2, 1984 and findings were found against cable pulling activities. On June 29, 1984, a final response to the findings was addressed in a I final report from W. R. Brown (RIM EDC 840629 702), Finding CC.5.1 stated that some areas of inspections were inadequale and the response was that additional training had been given lo all Craft Foremen, Craftsmen, and QC Inspectors involved in Cable Pulling activities at that time. A Training Effectiveness Committee with management representation had-interviewed the QC inspucLoru receiving the training to verify the knowledge lovel'of the inspector. Training was being provided to all craflumen umphauizing the necessity t.o adequately protect installed equipment from being damaged. ManagemenL overuight and surveillance were lo be focused on and increased in these areas until confidence was gained that requiremenLu were being mel, Reinspection' activities in the ..a .+.
m TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 q l PAGE 64.0F'144 l k olectrical areas were increased with more participation by-7 supervisory personnel to unsure the inLegrity of the f I inspection function. Inspection errors were being documented l and corrected. Specific feudback was provided to thu e { inspector on errors committed and genera 1' feedback regarding j Lhe errors was' being provided to the untire inspection l q I. group. Two follow-up internal Audit Reports (June'19, l ~ 1 l-1984 JLL-0 and August 16, 1984-DAC-3) were performed and no ) 1 4 l ( deficiencies were observed. The Nuclear Regulatory i l commission (NRC) did an Audit- ( A02860317016) from February r 10-13, 1986 and the final conclusion was no violations or deviations were idenLifiud. I 3 3.2 Issue - Electrical Inspectors impeded by craft from performing inspection. Craft personnul l intentionally interfering with the inspection i activily. (IN-85-046 N09, 00 05 005 003) (Generic) i Specific Evaluation r 1 i This issue was evaluated at WBN and SQN. Discussions were I held with an Electrical Quality Control Supervisor und i Inspector and an Eloctrical Ehgincoring Unit Supervisor and enginours. i 6 Discussion i' A discussion was hold with one inspector who was prevented from observing a "Q" cable pull. The individual stated that. another inspector was observing a "Q" cable pull in the fan l room, wievallun 737', AL a curlain point, thu craft could e ( not pull the cable in the conduit. They wanted to add more i men Lv the pull. I i ( ~ L.
' %/ ' TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 65 0F 144 The inspector told the craf t the procedure did not allow more i t men lo pull the cable because Lhis would excued its pull j s Lension. The craft agreed not to pull'the cable'and the. I inspector left the area. The inspector ruturned to the area with the individual interviewed by QACEG and tried to open the door, but it would not open, The individual lookud i through a hole in the door and found that the door was being I hvid by 1,hw craf t and approximately fif teen. mon were pulling on the cable, i l i The incident occurred in October 1982. An NCR was written on I p the cable and a nuw cable was..istallwd. Disciplinary action was taken against the general foreman and foreman involved. The uctual NCR number could nul be duturminud but Lho I individual found NCR'4413R and stated that this may have bsen Lhe NCR. I I The file pertaining to concern No. 00-85-005-003, dealing with the inspuctur being distractud and pruvunting him from l nulicing damage to cable insulation, referenced another concern, No, 00 85-005 014 by thu same individual which iduntified four specific cable / conduit runs. That concern sLalud in parL, "Insulallun was mistakenly cut off of a 440 j i vull cable and the insulation was reattached with electrical j Lape." i The concern went on to identify the cables as the power feed tu lhe Back Fluw Cate Huiut Motors at GQN. There are four such motors which are part of the Essential Raw Cooling Water (ERCW) SysLem. That same concern identifiud four cable / conduit runs as 1-PL-6370-B, 1-PL-6360-A, 2-PL-6370-B and 2-PL 6360-A and aluu iduntiflod the period of timo us ) mid-1977, i 'l l 1 -j
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 66 0F 144 Concern No. 00-83-005-014 is a reissue of Concern No. r. 00-85 005 001. The reason for reiusue was a correction of one of the cable numbers referenced in the concern. This concern was part of Construction Element Roport No. C010900-SQN and the particular issue is addressed under the P. heading "Insulailun Damage." Inspection records show that two inspectors were involved I with the cable visual examinations of the identified ) t cable / conduit runs in the period from June-September 1977. An interview was, held with an individual involved in the inspection of three cable pulls (1-PL-6370-8, 1-PL-6360-A, and 2 PL 6360-A). The interviuw centured around how an inspector may become distracted and how an inspector can cover the iriupucLionu, given the various areas cable is pulled through. Tho individual involved with cable pull i 2 PL-6370 8 inspucLion could not be inter viewed as he is no longer employed by TVA. The individual interviewed, who inspected three of the four cablev in question, slated that because of the various areas 1 a cable may be pulled through, the inspector could not always wiLness the entire operatiori. In his opinion, the point at issue could have happened. In reviewing the records it was noted Lhut the four (4) cable /condull runs referencud uro non-CSSC and rocoived acceptablo installation inspection Lhrough the period June SupLomber 1977. One cable, I-PL-6360A, received and passed a Hi-Pot Test. It was also found I, hat the cables have been de-energieud and, per ECN L5720, the electrical circuit for tho Dack Flow Gates has been converi.ed fr om autumatic t.oriLr ul Lu manual control. .c,
v-TVA-EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 67 0F 144 i Conclusion l I At WBN, the issue that Electrical Inspect' ors were impeded by craf t, from performing inspections is factual and identifius a problem, but corrective action for the problem was initiated' j before lhe employew concerns evaluations of the issue was e undertaken (class C). Disciplinary action was taken against t.he general foreman and foreman involved with L.he cable being pulled while the inspector was prevented from witnessing the pull. At SQN Lhe invuu could not be veriflod as factual, t However, as a side issue it was discovered that damaged cable inut,allation had bown repaired with electrical tapo.
- Also, it was discovered that Engineering did not reflect the status l
of the cablev as being du energieud on the design drawings. Cauuus The cause for electrical inspectors being impeded by craft l from performing inspect,ionu is a pour aLLitude 1.uwards and a l disregard for QA and QA requirements by construction pursunnel. Thw side luvuw sLemmed from a possible failuro lo follow procedures in performing an unapproved cable insulatiun repair. Currective Action 4 DNE evaluated the in ; ...m eriect cables wh. ch were rw{di r > ,' L c win CAID bcor icate acc rplable 80] 1 bA pondo iats %(.. in'JLullaLi o N urvico si' " 1977 and =dables w n-- i i t, s likel ia t i h m '.. u a perienced the worst conditions ineTuding uubmurgonew in waLor during Lhat time without any
TVA EMPLOYEE CONCERNS REPORT NUMBER: 00200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 60 0F 144 problems. Construction Engineering concluded that if thero was damage, it was not suf ficient tu impair the function of the cable and no further action is needed. With the additional information Fno hmarine ^
- 'able to QACE r
sea 4e4-- t Enginee -ing did d y nol t' Li c tt tdtf n he d asign hPf f to avaluate
- draQngs, med CATD 20 theproblemcon i t t ori in Liyht of
- t. heir rusonnxo_ '" f.hTD 80203-SQN-01.
The SQN Site Director has responded by stating: " Design Drawings 45N751-1, -2, -5 and -6 do rafluct the system status, however, the cloctrical circuit for the back i flow gates had buen convurlod fr om automatic control to manual control by the unit operator (L L5720) which ho has authority t.o do. The breaker for the ack flow gato hoist motors are being tagged th a 'cauti n rder'". Memorandum (RIMS 553 870312 I a Ling SQN plant manager to the project ong'n a - ch 12, 1987, provides clarification cu aluu of t,he backflow gate motors. This me r n part: "A review of I the usage of these bl e a ) that they are normally deonergized (admi s ive; a ed-out power supply) and are operated on te qL inspection / maintenance is required on t e i h nnel. This occurs at a fruquency o ti i Lime per refueling and t.hu cable is energi approx ately a 30-minute duration. Based on t.hese fac L ' , we r command that, this cable not bu repulled, but tha o plant maintain administrative control similar to those in existence. This will uave considurablu time and money while providing adequato assurance of cable l l 1 O
m 4 i-TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM i j REVISION NUMBER: 6 PAGE 69 0F 144 integrity over the life of the plant." Decause when the I subject cables are energizud during a refueling outage, it.is i 3 not considered a safety related function.- The response to the IR6 CATD has been concurred with by QACEG and no further action is I required. I, 3.3.3 Issue Inspections perfonned out' of sequence. Inspection of instrument location performed after other inspections have been accepted. (IN-85-296-001). 1 (Generic) i specific Evaluation This issue was evaluated at WBN and BLN. The following documenLu were reviewed for applicability to the issue: QCP-3.06-7, Revision 0, " Inspection of Electrical and Instrumentation Equipment Installation" and QCP-3.06, Revision 1, " Instrument Installation and Tagging." 1 Discussion i At WBN, QCP-3.06-7 " Inspection of Electrical and Instrumentation Equipment.. Ins tallation," Ruvision 0, j July 6, 1982, through current Revision 7, Octobor 28, 1985, was the procedure utilized for instrument installation i inspection during the timoframe of the issue. The procedure 'I did nul specify inspection uequence. The installation lucation of the instrument is upocified on the drawings and 1 the sequence of inupaction would not affect work. QCP-3.06 i Revision 1, " Instrument Installation and Tagging," Nuvember 17, 1986, 13-currently utillaud for inuLrument I i location inspections. .i j -_______________1___________ - _. - - J
T1 ) 1 TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 j SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 70 OF 144 1 At BLN, QACEG reviewed QCP-3.13 Revision 13, Equipment Installation." The procudure dows not upacify the sequencu of attribute inspections. All attributes-are inspected:and signed at one Lime, r f Conclusion _j [' i Based on interviews with cognizant personnel and review of. 1 [ procedures, the sequence of inspoction of instruments has had i no impact on hardware, therefore the issue is not factual. (Class A). j i 3.3.4 Issue - Hanger installed in the wrong location. (QCP -10. 3 5 28, IN-86 -299-001, 2850162004 ) - (Generic) - I i Specific Evaluation Thiu issue.was evaluated at WBN and 8LN. l The following documents woro reviewoE for applicability to i thw iuuue: NCR 2894; NCR 2768; NCR 2375R; NCR 2019R; WBN-QCP-4.23-3, Revision 6, " Support Location and Orientation"; QCP 4.23 4, Revision 6 " Visual Examination of Support Weld Joints"; QCP-4.23-5, Revision 6, "Gupport Shock 1 I Guppr essors"; QCP 4.23 6, Ruvision 5, "SupporL Springs"; f i' QCP-4.23-7, Revision 2, " Support Lubrication;" TVA memorandum R. Delay la R. Norris, March 8, 1984 (RIMS BLN840308377); 130 e l pipe support documentation packages. l Discussion AL BLN, QACEG verified, through review of TVA memorandum R. Delay to R. Norriu, March 8, 1984, that two pipo supports [ (2RHMPHGOO89F and 2RHMPHG0091F) were identified as mislocated i i t.. ..__._.=.______._m
v TVA EMPLOYEE CONCERNS REPORT. NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 71 0F 144 on NCRs 2894 and 2768 respectively. The NCRs stated that the deviations were caused ' by mislocalud control lines. The inspection reports accepting these hangers were invalidated L and ulher Engineering discipline units were directud to porform a review of features installed in their arcas and .1 write NCRs for any deviaLionu nuled. 130 additional supports were reviewed to determine if locations were correct, As a-result, hanger 2WDMPHC1138 was identified for a location deviation. However, after further evaluation _it was discovered this hangwr wau incorrucLly located by design, and was ultimately scrapped as documented un NCR 2989. At WBN problems with thw Hangur/Supportu Program have boon i identified on NCR 2375R, 2019R and.others with the not result l l that WBN-QCP 4.23 3 through-7 wur o lusuud. Lu butter durine l 1 hanger / support inspection. Personnel have buon trained in j Lhw procedures and a reinspection pr ogram has boun ins tituted. l l Conclusion 1 1 At both sitos, the issue of hangor location deficiencies is factual and identifies a problem, but currectivo action for I the problem was initiated before the employee concerns evaluation of the issuw was undertakwn (Class C). AL BLN the pipe supports identified in the TVA memorandum R. i .I Delay to R. Norris were dwlur minud to bu uut of location duo to an incorrect control line. AL WBN, initiallun of hunger ruinspuct.iun program, HLTS list, new inspection procoduros. and retraining of inspectors indicatu Lhat TVA has recognized thu problum and han' Lukun j steps to bring it under control. 1 I
l i TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM q REVISION NUM8ER: 6 4 .i PAGE 72 OF~144, .Cause j l At BLN, the problem resulted from.mislocated control' lines and l l . 'a design error. At WBN,- the inspection program did'not contain IR6-1 Jadequate. criteria for hanger / support inspections. 1 CorrecLive Action f Corrective action has been' implemented and completed at BLN. A LoLal of 130 addillonal supportu wuru reinspected. Of the-130 supports reinspected, one was 'noted to be mislocated. Howevur, thiu was altribulwd to a design error and not a construction error. Additional action-at OLN'is not required. I At WBN, lhw hanger reinupwcLion progr am will resolve the IR6 problem. I i' 3,3,5 Issuw Inspector u cannot calculate Lot que valuu convulsions when using extensions. (BFM-86-003--001) (Coneric) i ) Soucific Evaluation I_ This issue was ovaluated at WBN, SQN, DFN and BLN. t The TVA Special Training Guide was roviewed for applicability to the issue. Discussions'were hold with Mechanical, j Electrical, llanger, Civil, and Instrumentation Quality j Assurance / Quality Control personnel; Mechanical-Engineering-L personnel. l Discussion At WBN, discussions were held with cognizant supervisors;from MQC, EQC, HQC, CQC, 'and IQC Lo determine if Lorque: valuus - [ woro calculated by inspectors when using extensions on~ torque ~ l I l 1 L_ . ~. d ?
~ TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200-SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 73 0F 144 i wrenches. The discussions revealed that each inspection discipline uses an equation for determining Lorque value. The equations utilized are either from other TVA nuclear sites or from the Lorque-wrench manufacturer's information. The individuals stated that information for performing torque -l conversions was not includud in any procedure. A review of. j QCP 1.43-3, QCP 1.14 and G-32 revealed no instructions for calculating torque conversions when extensions or crow's-fuet are used. p At SQN, discussions were held with cognizant QA supervisors, r inspection personnel from MQC, and a Mechanical Enginuer. The discussions revealed that torque calculations for using extensions are provided by the responsible construellun ungineer directing activities associated with each workplan. QC personnel are not, responsible for delurmining Lorquo values. However, discussions hold with five inspectors revualed that all were aware of the nuud for calculating Lorque when oxtensions are used, and all had received training on perfor ming the calculations. At 8FN, interviews woro conducted with fivo QC inspectors curruntly parfornting Lorque tevling of structural steel / mechanical bolted joints to dotormino if they were familiar with basic Lurquing inspucLion requirements. Each inLerview consisted of asking general questions portaining to' basic Lorque inspection requirements and calculating the Lorque wronch sotting when utilizing attachmonLs. This calculation involves the application of the formula TW-(Ta)(L)/(L+ A), which was extracted from the TVA Special 1 -Training Guide dated May 4, 1986. A Lypical problem was ] given each inspoctor to solvo. Four of the fivo inspectors -i l
--g 1 TVA EMPLOYEE CONCERNS REPORT NUMBER: 80300 SPECIAL PROGRAM l REVISION NUMBER: 6 PAGE 74 0F 144 I explained they had not used the formula in delly inspections j .because attachments were not used on any connections that they inspected. All.five inspectors were familiar with the i formla and one inspector had ' the formula written on } Documentation associated with torque inspection which he carried to'the field. However, results of the intwrviews indicated'that none of the five inspectors could perform the calculation properly, as all answers were dif ferent and all-were inaccurate. l At BLN, the evaluation included discussions with Quality Control inspectors in Electrical, Muchanical, Civil and j i Supports and a review of pertinent procedures and various boll-up data cardu. The investigation revealed that some inspectors do not know how to do their own calculations for l Lorque valuuu when uxtensions aru ruquirud. Whun inspectors cannot do the calculation they must go to construction I 1 engineering and the enginuer will do Lho calculallon. This. ] calculation is not kept by the engineer and'the torque valuo that wau achiwvud is only recordud on the bolt-up data card. BNP QCP-6.19 Revision 1, April 22, 1982, " Bolted Flange ConnucLion" duws not give inspectoru any formulas to calculate torque if extensions are used. The basic algebraic j f uquation uvud by inspection personnel for calculating torquo, j L i when extensions are required, is-taken from a single page of I l paper adopted fr om an unknown source and is not part of any i b procedure. Because the formula is not contained in any formal proceduru, no training is conduelod in performing l' Lorque calculation. i L f, P
L TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 75 0F 144 Conclusion At W8N, 8FN, and BLN the issue was found to be factual and presents a problem for which corrective action has been, or is being, taken as a result of an employee concerns evaluation (class 0), At SQN the issue was not factual as QC personnel are not required to calculate torque values, j l Causes l ) l The cause for inspectors not being able to calculate torque values when using extensions is inadequate training for the task. There is also the problem of not addressing the potential hardware problems resulting from the inadequate training. This can be attributed to a lack of understanding by management of effective corrective / preventive action. Corrective Action At WBN, the Quality Control Departmaat t U. nas been l asked by Yuh'w CATD On9na i ^^;-a co de traininc program \\L 1 m e m* fo r,. iek e i orque wre ich with l Tl mm ( a c.o Al spect y equ' em - pro sciency g DNQA is also1_ro=r^--iL '. i or developing a procodure for the calculation of torque values when using an extension. At BFN, corrective action has been partially implemented, in that training classes were conducted for torque and conversion, however, no reinspection were performed on bolted joints made before training began. In response to CATO 80209-8FN-01, the Quality Assuranco Department-BFN has 4 M -e ,e 9 e '~ ____.____i._______
m C = j TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM ] REVISION NUMBER: 6 PAGE 76 0F 144 replied that, in accordance with the Gonoral Torquing Guido, i Engineering provides all Lorque values and factors for 7 extension values, where required. This response has boon ) concurred with by QACEC. I I At BLN, as a ro*"1+
- ".~ omving an for al procedure
[ go h iqi f gs xtensions the f artmen N t all p ocedures Quq1l t invbking to gireme wi __.. w include the ~ extbnsion ocuatinn .., appiicat.lon. This responded to CATD 80209-BLN 01 and QACEG has concurrud. 3.3.6 Issue - Numerous incidents of failure to follow proceduros. (IN 8 5-001-007, IN-8 5-43 7-005, IN-85 -243-NO3 ) (Generic) i Spocific Evaluation .j This issue was evaluat.J at WBN. l l i The following documenLu were reviewed for applicability to the issue: QCI-1.02, Revision 15, " Control of Nonconforming Items"; QCI 1.02 2, Reviulun 0, " Review of significant NCR action required to prevent recurrence." Discussions were l held with the Trend Analysis Group. L Discussion The issue is that procedural requirements are not being adhered with and is evident through review of reports documenting j conditions adverse to quality. Recent programs implemented by l L. .~. _x
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 77 0F 144 TVA indicate their awareness of this recurring problem. A1Lhough this issue was only evaluated at WBN, it was I considered to be generic to all other sites because of the root IR6 cause for the findings. t The reasons why procedures are not followed can be. grouped into l four major categorieu: (1) the procedures are inadequate and j cannot be followed due to unclear, conflicting or missing information, (2) the pervunnel involved lack the proper training, (3) poor attitude or lack of attention to quality, or (4) inadequate or nonuniform management enforcement.
- 1. The issue of inadequate procedures has boon addressed in Section 3.2.4 with CATDs issued identifying unclear, conflicting, and incomplete procedures as well as failure to institute hardware evaluations when procedures are found deficient, TVA has responded satisfactorily'to these findings and as listed in their corporate and respucLive silo nuclear perfor matice plans, has begun the task of upgrading and centralizing their-procedural system.
- 2. QACEG's Report 80300 addresses the issue of personnel training and explains currective action initialud by TVA.
This muru aggressive training program includes classes on Training ' Pr ucudure, PPT 301.005, "Why We Have Procudurus/ALLuntion Lu Detail," issued in July 1986, which has been attended by appruximalvly 95 percent of pervunnel, including supervisors and. management. Also the Corrective Action Plan for CATD 80604-WON -02, requires appropt late peruunnel to be trained in the importance and requirements of 10CFR21. In addition TVA has increased the lovel of l. raining and cerLificaLion r equirumunts l for Quality Control personnel, (Ref. QMP 102.5, " Training, Qualification, and Cer Lirication of Nuclear Quality Coritrol Inspectors, other than NDE.," Revision 0, July 1987). i l .i sw
U TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 78 0F 144 9..
- 3. poor attitude or lack of attention to quality can only bo p
alleviated by reaching the workers and inspectors on a personal i. basis and attempting to instill a sense of pride in workmanship and an understanding of nuclear indus try requirements. For thu craft, weekly " tool box" meetings are held for this purpose. These meetings allow workerv _ to become niore involved with solving and avoiding problems through teamwork. For QC, Quality i, Methods Instruction, QMI 810.9, " Quality Control Reinspection. l Program" was issued July 29, 1987, to outline a program which. 1 l evaluales each inspector's performance. Gection 6 of thiv l procedure states, in part, " Inspectors who regularly do not follow procedures will be identified," and "the QC Unil Supervisor discusses problems found with the responsible inuper or" and Lakuu" the app'ropriate acLion to correct Lhu problem." l
- 4. TVAs now policy of making unit supervisors, both craft and QC, 1
l ultimately responsible for QA violations occurring within Lhoir j groups has brought about a higher degrou of worker-manager l i involvement. Tho weekly muelings munLionod in 3), above, are a i direct result of this policy. t *' [ These and oLher measures recuntly Laken by TVA should reduce i these " numerous incidents" to an acceptable level attributable I { Lo human error. Tracking and control of root cause analysis l i l 1. and action to provent recurrence has been initiated through a IR6 new, ulandardizud CurrecLive Action Program that is deucribud i in the NQAM, Part I, Secticn 2.16, Revision 2, January 4, 1987. I ~ This program provides TVA with a standardieud procodure to I i tL. iduntify, evaluate and correct conditions adverse to quality .I t i L. e. t = Sg 6 md'h'
.v-l' 5 TVA EMPLOYEE CONCERNS GEPORT NUMBER: 80200 SPECIAL PROGRAM ) REVISION NUMBER: 6 j l PAGE 79 0F 144 i in a timely manner. The new system also provides for root l eduse analy313, trending, dnd generic applicability review to ensure that the full extent of problems'is identified and' i addressed. Implementation of the new Corrective Action Program was completed on schedule (March 31, 1987) by ONP. j i l Under this new program trend data to 'be input includes " procedure violation" as a cause code in order to retrieve and analyee the information to determine whether there is a 1 problem in this area, i l b l The trend analysis reports for the periods between November j i 1986 thru June 1987, showod thu following relationships of procedural violations vorsus total deficiency reports. writton: November throe percent; December uuvun porcent; January eight percont; Fobruary twenty-ono porcent; March Iifloen percent; April nine percent; May six purcunt und June eight porcont, j Through discussions with personnel directly involved with the Trend Analysiu Program it hau boun learned that when tronds bucome negativo, or more appropriately when the number of occurrences getu high, muutings are held. Thevo muelings involve performance action team members from craft, QC, l Enginuoring, and Trend Analysis and are hold L,o discuss thu trends with appropriate line managers who will take appropriate corrective action Lv reduce Lho occurrences to an acceptablo level. Recently, one such meeting resulted in the rutraining of all iron worker welderu in thu identification and acceptable removal of are strikos. 1 1 __.____m. ______A___----
TVA EMPLOYEE CONCERW9-REPORT NUMBER: ~80$00 SPECIALLPROGRAM REVISION NUM8ER: 6 PAGE 80'OF.144" These meetings are a very positive step forward. _ However, it r" was noted that NQAM Part I,'Section 2.16-requires'CAQRs to be.
- issued when adverse trends are identified, and no such'CAQRs could be found.- When questioned about this, Trend Analysis
( Personnel stated that: they had not, as' yet, been provided.a definition of adverse. f' l. Conclusion I:l The. issue is factual, safety-related, and presents a problem, but corrective action.for the problem was initiated before 1 -the QACEG evaluation of the issue was: undertaken. (Class C). TVA'has issued the procedure for the new Corrective Action Program. TVA has committed in the Management Review Guideline.MRG 12.16,.to evaluate the implementation of the t CAQ Program at TVA Nuclear Sites. 'The first scheduled j surveillance for WBN is August, 1987. In addition, NQA-ED-J ~ has a system of audits to verify that adequate measures are I taken to correct CAQs, An audit is scheduled'at W8N for October, 1987. Also, the program is being monitored monthly i I by the Quality Assurance Trend Analysis Group. However, as a side issue, due to'the slow development of the Trend Analysis 7 Program and the saturation of the TROI database with unrelated information, the timeliness and accuracy of the l trend reports' have been.affected and they are not as beneficial as they could be, t In addition, because no specific definition of the term " Adverse Trend" exists, trend analysis personnel.cannot determine when a CAQR is required. i E k .} L-
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIA.L PROGRAM REVISION NUMBER: 6 PAGE 81 OF 144 Causes l l The cause is a failure to follow established procedural I requirements and a failure to enforce QA requirements. Because I this type issue affects more than this subcategory, it will-IR6 aluu be addreused in the QA Category' Report (Report Number I 80000). l 1 l Corrective Action - { 1 1 Quality Assurance - WBN has been tasked with filtering out I the non-varety related information from the TROI database at WBN in an effort to expedito the trend analysis data. In l response to CATD 80204-WBN-01, action plans for this have l been defined and are currently being implemented. QACEG has l concurred. DNQA is revising the NQAM, Part I, suction 2.16 i Lo incorporate a definition of " adverse trend" in response to CATD 80204 NPS-01. Additional, corporale wide corrective action resulted in TVA's now corrective Action program which will eliminale ambiguous procedures and provide adequatu training of personnel. TVA's now policy of making unit superviuuru, both craft and QC, ulLimately respunuible for QA { q violations occurring within their groups has brought about a i higher degree of worker -manager involvement and an awareness of the need to prevent problems from reoccurring. 3.3.7 Issue - Engineering giving the "OK" Lo accept equipment by waiving required inspections. (XX-85-095-001) (Ceneric) i l l s .J
== 'l TVA EMPLOYEE CONCERNS
- REPORT NUMBER; 80200
_j SPECIAL PROGRAM j REVISION NUM8ER:. 6 PAGE 82 0F 144 I 'l i L Specific Evaluation 1 .i This' issue was' evaluated at WBN, SQN, BFN and BLN l l 1 j, The'following documents were reviewed for applicability to the issue: BNP-QCP-10.51, Revision 0, " Engineering q.. j Evaluallun and Interpretation"; QCP-1.14. Revision 20, " Inspection and Testing of Bolt Anchors' Set in Hardened Concrete and Control of Attachments-to Embedded Features. Discussions were held with Mechanical, Electrical, Civil and Receiving Quality CunLrul Personnul, and Construction Engineering personnel. J Discussion At WBN, QACEG reviewed over 100 inspection documents.to determine if any cunLained a nule fruin an ungineur which accepLed the inspection. None were found. However, during Lhe document review, two inspecLion cards were found which waived inspections of concreto quality and anchor I perpendicularly for conduil/ junction bux. support 0-CSP-292-3927/4 and 0-CSP-292-3916/3. The notes found on the cards sLalud that the inspections wore waivud "Per EEU," ~ and were-signed by the QC inspector and QC supervisor. f f i QACEC contacLed the EQC supervisor to determine the basis and justification for the waived inspections. The supervisor sLaled Lhal, before November 1986, EQC had misinterpreted a p noLe 43 on Design Drawing 47A056-1G Revision 1. The note i i, waiveu upacific inspeelions un certain conduiL/ junction box g 1 suppurlu. EQC had interpreted'the note as waiving all anchor 1 l j 1 l l ______._____,___._.___J
..m u TVA EMPLOYEE CONCERNS ' REPORT NUMBER: 80200 SPECIAL PROGRAM-REVISION NUMBER: 6 j 1 PAGE 83 OF 144 ' l inspections on those conduit / junction' box supports. 1 Consequently, an indefinite number of inspucLions wore waived i by EQC and the test cards were signed as acceptable. . { ~ l l In February 1987, an individual from EQC asked for clarification of note 43 from Civil Engineering. The reply was 1. hat only the specific inspections refurunced in the note j' were applicable, and that if other inspections were not i performud, a Condition Adverse Lo Quality (CAQ) existed. At SQN, cognizant supervisors from MQC, EQC, CQC, and receiving QC (RQC) were interviewed, Ali had boon at SQN for I a number of years. ' None had any knowledge of in:;pections i being signed au complete based un a note fr om engineering. At BFN, discussions woro held with cognizant personnel from Engineering, QC, and QA. Nunu.were awaru of inspectors I ) accepting and documenting work based on notes from engineers. They s LaLed that at BFN, no prucuduru'u exis t allowing engincoring interpretation of inspection criteria. Inupectors can requeul clarifications of codes and utandards by ruemo. If an inspector is not satisfied with the responso, J he hau the option of refuuing Lu uign-the inupucLiun document. Additionally, he may identify the condition on a j Condition Adverse Lu Quality Report (CAQR).. 1 i AL BLN discussions with QC personnel indicated that three or more years ago, when QC and Engineering wuro one o rganiza t ion,- instancos such as that cited by the CI could l have uccurred. However, no spucific examplus could be l l l ~* l e -_-________--_.-m.---_--- 2.
m - TVA EMPLOYEE CONCERNS-REPORT NUMBER: 80200 SPECIAL PROGRAM-REVISION NUMBER: 6 c. i PAGE 84 0F 144 ( 1 recalled. The individuals further stated that during that time period an inspector may have merely been relying on his r-l supervisor, an engineer, for guidance. On June 24, 1983, the Manager of Engineering, Design, and Construction issued a \\ memorandum (RIMS EDC 830624 001) titled " Responsibilities," which may have led to a misunderstanding of requirements. The memo was intended to define the responsibilities for authorizing changeu to design requiremenLu and interpreta' ting [ acceptance criteria. The memo states in part, "This position l I-should nol preclude dialogue belwuun Lhu construction proJuct and the design project, nor should it precludo askiner for adview where help-is newded." l { ] ) The Manager of Construction / Manager of. Engineering issued a l 1 second memorandum (RIMS OEN 841123 001) dalud Novumber 23, 1984, also titled " Responsibilities." The second memo t supersudud the firsI, and providud furthur delineation. and { clarification of responsibilities The second memo states in part, (in rugards to the first memo)" Lhis general I interpretation still leaves many areas undefined and subject t Lo disagreement as to who may establish requirements, make 1 interpretations, and approve changes." On June 24, 1985, BLN [ isuued DNP-QCP 10,51, Revision 0, "Enginuoring Evaluation and Interpretation", referencing the memo of November 23, 1984. The purpose o f QCP-10. 51 was to provide a meanu of l documenting engineering interpretations / clarifications of j requirements in documents such au drawings, specifications, inspections, procedures, and records. i e .=0 !L. e m _____.m_____...__---- -m---.------
n g-. p +- 1NA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM ~ REVISION NUMBER: 6-PAGE 85 OF 144~ Conclusion ' The issue was found ' factual at BLN but corrective action was 1 inillated before the umployuu concerns evaluation of the 1 issue was undertaken (Class C). The issue was not factual at 'l SQN, BFN, and WON. AL WBN'a vide issue was identified whuro-IR6 required inspections for concreto quality and anchor i perpendicularly were mistakenly. waivud on an indefinita. I i number of conduit and junction box supports. I Cause [ The causo of the problem at BLN was the lack of. clearly .I defined responsibility and. authority for changes to l J inspection requirements. As a result, inspection attributos IR6 Lhat should have beun purformed woru waivud. Thu uidu.issuu I at WBN resulted from the lack of clear direction regarding I required inupuctions. I i Corrective Action BLN issued QCP-10.51, "Engincoring Evaluation'and InLurprulation," Ruvision 0, as a moans Lo control und document engineering interpretations / clarifications whero requirements are subject Lo inLurprutation. As a rusult of misinterpreting note 43 on drawing 47-A-05-1G and the j subsequent waiving of inspections for anchor purpundicularity and concreto quality, W8N EQC issued CAQR WBP870405 and WBP 870407 Lo DNE. DNE is to uvaluate Lhu problem via the CAQRs. QACEG issued CATD 80209-WBN-05 to track the CAQRs to l closuru. 9 M 'e g n_...
.w TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUM8ER: 6 PAGE 86 OF 144 l i l 3.3.8 Issue - Inspectors' job attitudes and. behavior questionable. I Contentions include. inspectors. coming to workdrunk, IR6 r.. inspectors being malicious and vindictive towards the craft, and excessive overtime affecting morale. (IN-85-445-012, PH-85-010-002, XX-85-065-002) (Generic) t I Specific Evaluation l l This issue was evaluated at WBN and BFN. ( l The following documents were reviewed for applicability to the issue: Standard Operating Procedure SOP-QMO-03, " Quality Control Reinspection Program"; W82.2.5, Section B, " Notes from Payroll"; TVA report PH-85-010-002. Discussion were l held"with Inservice Inspection (ISI) Personnel, Civil, Wolding, and Hanger QC Supervisors. Discussion At BFN, discussions were held with an ISI supervisor and several ISI inspectors to determine whether an individual reported to work extremely hung-over or drunk during the l summer outage of 1983. This had, in fact, occurred. The identified individual was a contract employee hired for the { outage and did not have an inspector's responsibilities. His duties were of a support type to enable the ISI inspectors to I carry out their functions. The individual was employed for approximately two to three months by TVA working in the capacity stated above, before he was entered into the Employee Assistance Program. After completion of the l program, the employee in question did not return to the ISI l l group. I f e.g _m
TVA-EMPLOYEE CONCERNS ' REPORT NUMBER: 80200 g .SPECIAL PROGRAM REVISION NUMBER: ~6 ) PAGE 87.0F 144 QACEG evaluation did not identify instances whero=other members of the ISI group came lo work hung-over or drunk. Additionally,. discussions with supervisors indicated that such a. condition would not be Lolerated. At WBN,- QACEG contacted QC Civil, Welding, and Hanger Supervision regarding excessive overtime affecting inspectors morale. -The QC supervisors. stated that most inspections i personnel welcome overtime as a means of supplementing
- income, However, they'also indicated that the. possibility exists that to uome? individuals, overtime may.have been a concern and could affect morale and inspection adequacy.
H Inspeelion personnel at WaLLu Bar presently arujrequirod to abido'by NRC overtimo restrictions as outlined in.WB 2.2.5,. SecLion B " Notes fro'm Payroll," which paraphrasuu NRC. overtime restrictions. The project,is hold accountable by-the SiLe Director and-.muvL juulify.Lo him why it is nucouvary to work overtime hours in excess of thoso speciflod, 1 i Regarding inspecLlon adequacy the Inulitute of Nuclear. Power IR6 Operations (INPO) conducted.a construction project ovaluation q al W8N in 1985. Finding (QP 3.1) (RIMS P01850826 603) in the INPO Report statos: " Quality Inspections sometimos do not ensure that hardwar e is inulalled in accordance with design. Some.previously inspected and accepted items woro' determined -l Lo contain deficiencies. Some inspectorv were noted not fully complying with inspection procedures. In some cases, Lhe acceplance criteria had noL been provided or was not clearly understood," j I l i ..J l l -0 i
-m- _v q v TVA EMPLOYEE CONCERNS- ' REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 l PAGE 88 0F 144 ] i INPO recommended that the project. intensify the monitoring of 1 QC inspection ef festiveness through increased involvement of - a l supervisors in the field. The Project Quality Organization 1 1 . responded to the INPO recommendation by issuing Standard 1 Operating Procedure SOP-QMO-03 on May.18, 1986, which i outlines the W8N Construction " Quality Control Reinspect' ion ) I [ Program." Utilization of SOP-QMO-03 provides. for the idunLirication and revolution of improper inspections. This j ' instruction applies to the reinspection of work performed by inspection personnel within the WBN Construction QC Inspection Units, Another portion of the issue alleges that some_ inspectors exhibit malicious or vindictive attitudes which cause delays and undue rework. A TVA informal report titled " Employee i Concern PH-85-010-002" documentu inLorviews with 76 randomly selected craftsmen and completely' discounts the statement. Discussions by QACEG with general foremen and superintendents of various craf ts (Electrical, Piping, Instrumentation, and. l l l l Sheetmetal), and with pervunnel from the HQC group resulted j in a general consensus that supported the TVA informal report I and, therefore, QACEC t.uncuru. One individual (Piping Superintendent) interviewed did state that he had encountered [ "upileful" QC inspecLuru and had conLinuvuu communication problems, but that the words malicious and vindictive were Lou u trong. In responue Lo Lhis superinLendenL's fuelings, QACEG elected to expand the evaluation to include discussions -{ with his avviulants and the QC discipline he namud. These added discussions again complemented the TVA informal report, and IL is concludud that any such feelings are isolatud. 1 = d
-ms g TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM . REVISION NUMBER: 6 PAGE 89 0F'144 Conclusion At BFN there was one instance of an individual coming to work drunk or hung over (Class C). Other portions of the issue were found not factual. The issue was not verified as IR6 factual at WBN. I Corrective Action The identified individual was removed from the:ISI Group, The incident was an isolated happening resolved by UFN management, i 3.3.9 Issue - _ Electrical Inspections inconsistent and/or not performed. (IN-85-119-006, IN-85-458-005, EX-85-073-002, HI-85-105-001, PH-85-014-002, t I IN-85-993-006) (Site Specific - WBN) l k Specific Evaluation This issue was evaluated at WBN. The following documents were reviewed for applicability to the issue: QCI-3.05, Revision 11, " Cable Installation"; QCP-3.05, Revision 28, " Inspection of Cable Installation"; Construction f Specification G-38, Revision 6, " Installing Insulated Cable j to 15KV"; NCR 5857; NCR 6463; NCR 6464; QCT Roport l IN-85-119-006. I Discussion A portion of the issue deals with the allegation that required acceptance attributes (tests) were not performed and } no deviation or change documents were prepared to address the omitted tests, t 1
- se TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 l PAGE 90 0F 144 i i QACEG reviewed ERT report IN-85-119-006, March 31, 1986. The results of that investigation verified that Inspeellun Rejection Notices (IRNs) were written to document that certain Lustu were nul performed. These IRNs were subsequently voided and tests cards were destroyed. After additional document reviews, it could not be determined thal l all applicable' inspection attributos from the destroyed test cards were subsequently per; formed. t i IRNs were' reviewed'at the EQC department. A random selection I { revealed that voided IRNs did exist. These IRNs were to be j addressed in NCR 5857. Howevor, voided IRNs were located in EQC's file which were not addressed in this NCR. In addition, IRNs woro located which have been open for over ono - year. A walkdown of randomly selected v'upports identified on Lhe voided IRNs was performed by EQC, The results of this walkdown identifiud Lhat of 40 uuppurls reinspeci.ud by EQC, 35 were rejectable for one reason or another, 1 l l After reviewing theue rusullu, un additional walkdown was performed by EQC on randomly selected electrical supports which were nul idenLified un vuided IRNu, This walkdown was 4 performed in unit 1 insido containment, Of ten support: 1 reinspected, nine were rejectable. The items rejucted from l both walkdowns are addressed on NCR 6463. The NCR states Lhat it is a significant CondiLion Adverse to Quality, and it l has been reported to the NCR under the rules of 10CFR50.55(e), i. Another portion of the isuue indicated thal, during the summer of 1984, an inspector had documented some inspections with no physical inspucLion of hardware for work releases on unit 1 conduit throughout the plant.
4 c TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200-SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 91 0F 144 QACCG utilized QTC ERT Report PH-5-014-002 in the ovaluation of this issue since it deals with thu same subject..The~QTC evaluation consisted of interviews with the concerned individual and it was concluded that neither Lho specific instance nor the identity of the inspector.could be provided. The scupe of QTC's evaluation concentrated on unit I 1 conduit work releases during the summer of 1984 QTC l reviewed thirty work release forms, six of which were related to conduit rework and QC inspections in the unit 1 Reactor Building. QTC iniLiated a field walkdown of the above six work releases and deficiencies were identiflod. WBN Quality Control lusued NCR 6464 Revision 0 on November 14, 1985, identifying the deficiencies which included damaged flex, ~ span violations, wrong uleo conduit and improper identification. NCR 6464, Revision 0, was still opun as of 1 January 28, 198'7. - i The QACEG evaluated inspection documents to determine whether adequaLu und convistent instructions wuru providud for i ~ I electrical disciplines. The Division of Enginocring design i drawingu that were reviuwed provided adequale implomontation I notes and cross-referencos to specifications and other drawingu. SufficienL dimensions and dulailu were present to minimize the amount of drawing interpretation that would be ruquired. The QCPu and QCIs that were ruviuwed providud detailed inspoction attributes with quantitative critoria where apprupriale. The QCPs spelled out thu inspection requirements in lieu of referring to codos or other documents for the inspection criteria. 8 J i
TVA EMPLOYEE CONCER.S REPORT NUMBER: 80200 i SPECIAL PROGRAM' REVISION NUMBER: 6 -} I 1 PAGE 92 0F 144; l Revisions of QCPs wore reviewed for the time. period of July l 1972, Lu the present. Historically, Lhe procedures have improved with regard to clarity and now provide a clearer, more concise breakdown c.* Lhe aLLributes Lo be inspected. 6 Older revisions often refer to other proceduros or specifications for the accept / reject criteria. The procedures have improved, but'the older versions did provide ~ adequatu ' ins tructions Lo facilitale consis tent inspection. 1 l. An additional portion of the issue deals with an allegation l Lhat it was a common. practice to " accidentally" by-pass a QC I hold point with rospect to cable pulling activitios in 1974. l QACEG discuuved this with a QC Electrical Supervisor and two j QC Electrical leads. Deforo March 22, 1970, no QCP oxisted-for cable pullu. ConutrucLivn forceu performud the work and engineering personnel performed the " inspections." It was I commun pracLice for ConvirucLion lo noLify Lhu engineur before the pull. After the engineer verified pull completiun, the pull LickwL/ report was signud by both tho craft supervisor and the engineer. The abovo referenced personnel stated that no " coercion" was required for the ) engineer to sign-off pull completion. It was further stated f that in 1974, WaLLu Bar was in Lhu initial construction stagu I and no "Q" cable pulls woro performed, i I t I l Another part of the invue concerns electrical junction boxes l being accepted without the "01" test (anchor bolt verification) performed. Based on a review of availablo data j in the filos, it has been determined that there is a problem i i with the electrical junction boxus and their supports. An evaluation was mado by both QACEG and EQC which indicated that anchor bull verification was not performed. This is in violation of QCP-1.14 " Inspection and Tosting of Bolt Anchors _ _ _ _ _ _ _ _ _. _. _-uw--A----__,.--
v 4 I TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM i REVISION NUMBER: 6- .i PAGE 93 0F 144-As a result of the initial QACEG evaluation, NCR 6463 was issued and walkdown procedure WBEP-WP-3 was formulated, that includes a complete walkdown program for all junction boxes dftd SupporLU. l Another aspect of this issue involved the lack of sido-wall prwsuuru values during cable pulling operations. A review of Electrical Procedures QCI-3.05, Revision 10 and i QCP-3.05, Ruvision 25 revealud that until Revision 6 of General Specification G-38, September 15, 1985, there was no i program for vulablishing side-wall pressuru valuus and I considering them when maximum allowable pull tension was IR6 determinud. Discussions with EQC, Construction, and i Engineering personnel confirmed this fact. A sidc-wall prussure value group was eutablishud in Augus t 1985, to formulate side wall pressure values for each cable pull. These valuws are now included in dulurminations of maximum I alluwable cable pull tension which is provided in cable pull IR6 packagws iri accordance with QCI 3.05, Ruvision 10. I In order to establish whether or not there is a problem with cable pullud befuru Gwplumber 1985, 81 conduits wore chosen by Engineering as " worst-case" configurations. Knoxvillo's Electrical Enginuaring staf f develuped side--wall prussure value calculations that wore four to five times greater than cable manufactururu recommendations. An independent third party, David L. Silvers and Associates, Inc. has concluded Lhal Lhe TVA LesLing of thw "wors t -case" configurations was satisfactory. h t
TVA EMPLOVEE COWCERMS REPORT BUMBER: 80200 .SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 94 0F 144 f At present the NRC has not concurred with TVA's calculations. Cons tr uc tion Calugory Evaluation Group (COCEG) investigation into this concern resulted in the generation of CATD 10900 NPS -01 Lu Lrack this problem. l Conclusion c-1 The issuo of Electrical inspections being inconsistent and/or j not performed is factual and presunts a problum for which corrective action has been, or is being, taken as a result of an employuu concerns evaluaLion (class D). Causes The cause is failuro to follow procedures in that required acceptance Les lu wer e rio L per furmed. Tiiiu cari aluu be aLLribulable 'to a lack of attention towards QA requirements. There is also a failure lo eulablish an aduquato ulectrical inspection program. CurrecLive Action The COCEC issued CATD 10900-NPS-01 to track the problem with side-wall pressure values. NCR 6464 was issued to address the problem with rejectable supports identified during wa l kdowris. This problem was reported in accordance with 10CFR50.55(o). CATD 80209-WBN-01 was issued to track NCR 6464 Lhrough cluuure. The response from WBN Engineering states that the NCR will bo tracked under TROI. This CATD will remain upen unLil NCR 6464 lu acceplably closed. I L_
TVA EMPLOYEE. CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAN REVISION NUM8ER: -6 PAGE 95 0F 144 l l 'l WDN issued NCR 6463, Revision 2, on February 10, 1986, 1 deveribing discrupunclus noted during a physical walkdown and I " reinspection" that was'requestod by investigators of QTC and ,l the Employew Rwuponsu Team. EQC inupectors performed the actual reinspection. The original inspection of these supporLa was performed bulu:een 1978 through 1984. Tho ~ resulting NCR described the following deficiencies: no i livling of FCRu and/or varianceu that apply to the supports, j supports not identified properly, support types do not match documentation, supportu located in the plant are not listed ) in the support printout, and supports are listed on tho-fj printout that are not installud in the plant. Other -) 1 miscellaneous problems were identified. This condition was a reported to the NRC under 10 CFR 50.55(e) and identified as l 1 NRC open item 3900/86-014. I WON iusued "Slandard Op'urating Pr ocedure" SQP-QMO-03 " Quality Control Reinspection Program" on May 18, 1986, which applies Lu 1,he reinspection of work perfor med by inspucLion personnel within the WBN Construction Quality Control Inspection UniLv. This prucedure providwu for the idenLirication and resoluLion of improper inspection. f i a The correcLive acLion for duriciencies in eloetrical junction boxes and supports is included in Walkdown Proceduro WBEP-WP 3 by DNE, Implementing Lhis procedure will identify j and currect any unacceptable junction boxes and supports that l may havu been installed in the field. ______________m_ _--m__---
7 _. TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 i SPECIAL PROGRAM . REVISION NUMBER: 6 c. PAGE 96 0F'144 l 3.3.10 Issuo - Electrical inspection results not documentod. Tentu performed per the. procedures but with no requirement to document the results. (IN-86-252-XO3, IN-86-259-015') (Site Specific - t WBN) { Specific Evaluation This issue was evaluated-at WDN. The following doyuments were reviewed for applicability to the issue: QCI-3.06, Revision 1, " Wire and Cabl'a Termination"; QCP 3.06, Revision 8, "Inspec tion o f-Cablo Termination"; IEEE-308-1971, " Standard Criteria for Class IE Electr ical Systems for Nuclear Power Cuneration Stationu"; and QCI-1.07, Revision 5, " Work Roloase " Discuusion A review of QCI-3.06, Rovision 1, " Wire and Cable Ter minaLion," and QCP 3.06, Revision 8, " Inspection of Cablo Termination," together with Industry Standard IEEE-300-1971, "SLandard CriLeria for Class 1E Electrical Systems for Nuclear Power Generating Stations," did not discloso any i l requirement for recording megger ruudings before terminating low voltage cable. Discussions with both QC and Construction Engineering Electrical personnel revoaled that cablos are normally meggered before termination..This.is an industry accepted standard practice and a pra'ctice at WBNP.
- However, there is no procedural or electrical codo requirement f
mandaling LhaL Lhe results be documented. l 1 i t J
v. s TVA EMPLOYEE' CONCERNS REPORT NUMBER: 80200; l SPECIAL PROGRAM 'i REVISION NUMBER: 6 PAGE 97 0F 144 l .j A review of the applicable procedures was mado.to determine if any documentation was ~ required for relugging cable. QCI-1.07, Revision 5, states that no Work Release is required for work under the jurisdiction of QCI-3,06-3. Only the completed determination is required to be inspected and I documented and this was done in compliance with QCI-3.06.3. Conclusion i The issue that Electrical inspection results are not being documented is factually accurate but what il describes is not a problem (class B), j 3.3.11 Issue - Galvanized junction boxes installed in lieuauf field fabricated, painLud junc Lion boxuu. (IN-85-913-002) I (Site Specific - WON) -l Soweific Evaluation l This issue was ovaluated at WBN. l I 1 I The following documenLu were reviewed for applicability to l Lhe issue: NSRS Report I-85-524-WON; QCP-3.03, Revision 20, "InupecLion of Electrical Conduit and Junction Boxes"; i Construction Specification G40, Revision 9, " Installing I Electrical ConduiL Gystemu and Conduit Boxes." Discussion NSRS Report I-85-524-WBN investigated the concern that Electrical QC accepted juncLion boxuu (JBs) that did not { comply with G-40 requirements and the Electrical Standard Drawing (IN-85-913-002). NSRS found that EQC was correct in .{ accepting either painted or galvanized JBs. i i j
.u. l TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 ' l^ SPECIAL PROGRAM REVISION NUMBER: 6 .i ' l PAGE 98 OF 144 I l l l QACEG concurs with this-finding based on the.following: l j 1 1 I a. Specification G-40, Revision 9, Section 2.0 - i t: \\ " Materials," states " materials.. shall meet the { requirements of an approved recognized s tandard; and l l shall be compatible with the environment and l configuration in which they are'to be localud." Note: The National Electrical Code (NEC) is an approved,- recognized utandard and cites in part: "Motal boxes, i conduit bodies and fittings shall bo I currosion-revistant or shall be well galvanieod, enameled or othorwise properly coated inside and out to prevent corrosion. " The NEC allows for oither painting or galvanizing to provido corrosion i proLection. Specification G-40 Revision 9, Section 3.3.2 - " Painting," I applieu only lo field-fabricalud juncLion boxus and, according to the EEU supervisor and an Electrical engineer, there are l [ no field fabricated, galvanized junction boxes at WBN. b. QCP-3.03 Revision 18, Section 7.2.2, stated in part: " Interior uurface of the junction box is painted or I galvanized." [ [* A( ei I 4 Conclusion t SC Fs g (Based on the NSRS Report, discussions with EEU personnel and P
- 'b--
- ttview of applicable procedures this inuue was not verified as factual. (Class A) l em e {u.g
-__s, 4 i 4 TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 l SPECIAL PROGRAM i REVISION NUM8ER: 6 PAGE 99 0F 144 .i 3.3.12 Issue - Nonconforming instrument lines (slope / cleanliness). Installed instrument venning lines do not maintain required slope / cleanliness requirements. I (IN-85-985-001, IN 135-003, PH-85-001-008, PH 001-009, PH-85-001-003 ).(Site Specific - WBN) i Specific Evaluation / This issue was'ovaluated at WBN. f I The following documents were reviuwed for applicability to 1 l the issue: NCR 6172; NCR 6359; Construction Subcategory 'l l Report 17300; Instrumentation Project Report. Discussions ] were hold with an instrumentation discipline engincor and QA I instrumentation personnel, j I i l l Discussions I -j 1 The QACEG ovaluation disclosed that an Instrumentation l Adminiu LraLive Hold was placed on WBN unit 1 and 2, on l October 25, 1985. This hold was established to provent the continuation of j acLivillou Lhat had repeaLudly fallod to produco a vurified/ documented quality product. The hold portained to the installation, inodification, and inupucLlon of instrumentation and instrument linos. The hold states, in part, "This ' hold' will remain in ef fect until we can assure TVA Management, our employcos, and the public that Instrumentation syslums will be installed, modified, and inspected in an excellent manner and will provide reliable service." i l ____ _ ______________ _ _m
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: - 6 PAGE 100 OF 144 The WBN Instrumentation Program has been the subjuct of indepth evaluations since 1985..The Instrumentation Project was formed in October 1985 to identify and resolvo deficiencies within the program. Their reports, along with { an NSRS Investigation Report and subsequent NCRs, have documented problemu including, but not limited to, slope and - t j cleanliness deviations. These problems were noted in all areas of.the instrumentation program, including design, installation, and Quality Assurance and collectively led to the issuance of stop work orderu in January 1987. Beforu lif ting the stop work orders,- J a new program will be implemented with emphasis on procedure and specification revisions and more intenso training of craftsmon and Quality Control'inspec~ tors. In addition, instrument line Leuling will assure iniLial cleanliness. Another part of the issue contends that instrument lines with nonconforming slopw, were vigned of f by a QC inspector who had previously signed off inspections without inspecting the item. QACEC contacLwd QuallLy Cuntrol Civil, Instrumentation, Wolding, and Hangor Supervis' ion regarding an f InulrumunLalion inupucLor uigning'off inspections without inspecting the itom. This was confirmed for only one inspector and involved a single incidunt. The supervisors know of no other situation whora the instrumentation inupwetur acewplud an item without parforming the inspection, f Conclusion The issue of nonconforming instrument lines is factual and idunlifies a problem, but corructive action for the problem was initiated beforo the employoo concerns evaluation of the issue was undertaken. (Class C) i e e .ww
y__ J 1. ) TVA EMPLOYEE CONCERNS REPORT NUMBER:.80200 SPECIAL1 PROGRAM REVISION NUMBER: 6 i PAGE'101 0F.144 Dased on. review of NSRS reports, NCRs 6172 and 6359, the } Construction Subcategory Report 17300, and the - ) Instrumentation' Project Reports, QACEG has found this issuo Lo be factual. Corrective actions, however, have boon mandated and discussions with discipline engineers and QA i personnel reveal that retraining, reinspection, and l specification and procedure rewriting has begun, i Causu The cause of nonconforming instrument lines l (slope /cleanlinous) is aLLribulud to managemont's failure to establish an adequate quality assurance program-for. ins trumentation that included indus try, pr ocuduro, and i specification requiromonts. Thoro was also a' lack of I puruunnel training. Failure lo Lakw Limely and uffucLivu (R6 l corrective /proventivo action compounded the problem. I i I I i i Corrective Action The Instrumentation Project was established to identify and ruualve instrumentation duficiencius. This projuet is i ongoing. Corrective action responsos for NCR 6172 and 6359 will be provided upon conclusion of Lho projuct work. 3.3.13 Issuo - Instrument sottings falsified or not documented. Valvus and t.ransmitter adjuvLmunLs made without results being documented.(PH-85-002-X23, WBN-0054) { (Site Spucific WGN) e
-- x, y TVA EMPLOYEE CONCERNS REPORT NUMBER: 00200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 102 OF 144 1 1 Specific Evaluation f I This issue was uvaluated at WBN. r. f, The following documents were reviewed for applicability to j Lhe lusue. Maintenance Request A 579202; Instrument ( i Maintenance Instruction IMI-100; Calibration Test Instruction _l i TI-56.18; and QCT 3.13, Revision 5, " Hydrostatic Pressure .f f Testing of Instrumentation Sensing Lines " Discussions were held with the Instrumentation General Foreman. Discussion l i The QACEG investigation of the adjustment of a Lovel Transmillor (Number 0 LL 18-99) without documentation, includod discussions with the Instrumentation General Foreman. TVA had inuued MainLunance Requeul (MR A-579282 on August 18, 1986, to troubleshoot and repair or replaco'the level transmiller in uccordance with Iris tr umunt Maintunancu Instruction IMI-100, then calibrato in accordance with Test i InuLrucLion TI 56.10. This MR ruplacud MRu A507981 and A508532, which were subsequently cancelled. 3 I d i The IMI requires Lhal an MR be lusued to perform wor k and l that all work performed is recorded on the MR. Instrument mechanics have training sesulons in the use of the IMI and MRs. The lovel transmitter in question was calibrated and 3 the results documentud on MR A-579282. The CI alleges that personnel falsified settings of valves and gauges so that it would appuar that all Lubing was teutud. L, m
~-- g TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUM8ER: 6 PAGE 103 OF 144 QACEG discussions with an Instrumentation Engineer, a Quality-Assurance Supervisor, and the ANIS did not produce any additional information or documents to support the. allegation. A review was performed of QCI-3.13 Revision 5, " Hydrostatic Pressure Testing of Instrumentation Sensing Lines." The QCI t requires that during pressure testing, Quality Control i Inspectors and the ANI verify boundary limits, valve number i and posillon (open or closed). Pressuru gaugus are verified 4 for range, manufacturer's identification number, calibration date, calibrativu due date, and ASME Section III calibration' Verification Reports. This information is recorded on Presuure Test Operallonu Shuels (part of. test package) which aro Life of Plant (LOP). documents. Rocent discussions with the Inspector Conural's (IC) of fico revealed that a separate.ovaluation will be' performed by the IC and documented in report 60300 regarding the falsification allegations. I Conclusion The issue of instrument sottings being (disified or not boing documentud was not verirled as factual. (Class A). This finding may change based the results of the IG investigation. l 3.3.14 Isuue Walkdowns are not adequale unuugh Lo identify deficiencies. (HI-8 5-069-NO3, IN-8 5-027-003, i IN-05-442-000) (SILe Spucific - W8N)
v-TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 104 OF-144 e'l Specific Evaluation . r., t I This issue was ovaluated 'at WBN. t l The fellowing' document was reviewed for applicability to the i invue. G 20M 4.M.4.1, Revision.1, "Proceus Specification for ( l Surface Cleanliness of Austenitic Stainless Stoel Piping and -{ l t Components. l i Discussion I i Becauso of the vague description of the issue, decreased scope of walkdown, QACEG pursued discussion with the CI after getting approval from the Inspector General's Office and was ablu to obtain additional infonnation. The CI specified that the issue applied to' incorrect installation of ferrules in compression fittings that had been ins talled in various safety-related and non-va f e t.y-related u y a tems. ( The CI further stated that in addition to construction i l wngineuring dueruauing walkdown ef forlu, ellhor prior to or af ter installation of forrules, craf t personnel are not being properly L.rainwd in thw installation of those furrulus and quality control inspection does not include verification of correct installation. i ) l L I L-
- g l TVA EMPLOYEE CONCERNS. REPORT NUMBER: 80200 i SPECIAL PROGRAM l REVISION NUMBER: 6 PAGE.105 0F 144 Dased on discussions with the CI, the CI apparently construed informal walkdowns and advice by Engineering during installation (especially of ferrules) as formal "walkdown" activitius,- In fact, they were more information type-walkdowns performed as part of the routine job function, The QACEG evaluation of the issue concluded that these walkdowns were not required by procedure at.the time the concern was
- raised, QC inspection during this timeframe was limited to final inupection for instrumentation lines and associated equipment and flushing and/or hydrostatic testing and did not include compression fitlings.
i Another aspect of the issue alleges that QC walkdowns were nul complule unough Lo verify design installation in the j field. The concerned employee was not specific as to the type, locallun, or Limurrame of the walkdowns'in queulion. Conclusion The issue of walkdowns not being adequate is factual and identifios a problem, but corrective action for the problem was initiated before the employee concerns evaluation of the iusue was undurlakun (Class C). Cause The cause of the issue is a result of management's failure to S establish an adequate ins tallation and inapection program for compression fittings. ge s u__ __.__________________..___________________________.__m.___
l TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 106 0F 144 .F* ~'l Corrective Action i i ) f' I l As a result of wmployev concerns and various NCRs and i l Significant Condition Reports (SCRs) pertaining to l l r. J I,, compression fitting installation, Lhe Instrumentation Project I Group conducted an investigation and evaluation and l i . [ instituted a corrective acLion plan Lo revise and improuw IR6 l i' 4 TVA's compression fitting program. The; corrective action I l plan also included a revised training program for craf L' i l i personnel, engineers, and QC inspection personnel. The now I program is explairtud and documented in the " Watts.Bar l J J Instrumentation Project Report and Transition Plan." l j \\ 3.3.15 Issue - Instrument Panel rejectud due to Bulling Tolerances. Entire Panel unacceptable due to a floor colt out of- [ Lolorance. (IN-85-175-001) (Site Specific - WBN) 'l Specific Evaluation l l l This issuu was evaluated at WBN. l 1 i The following documents were reviewed for applicability to the issue: QCP 1.42 2, Revision 4, " Bull and Cap Inupuction for Bolt Anchor Assembly"; Orawings 47W600 Series 47W600-14 Section "BG" Genwral Notes, 47WO61-13A Detail "E" (bolting size), and 47WO61-1A; NSRS Roport IN-85-175-001. Discussion i The issue is that an entiro instrument panel was rejected becausw one floor bolt was vut of Lulurance by 1/64." The NSRS and QTC report was reevaluated by QACEG and found to be corruel in stating: l l. N l' L I _.______m__m_____._.--
x t l TVA EMPLOYEE CONCERNS. REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 107 0F 144 "The Quality Control Inspector has no choice except to reject dny item which exceeds the allowable tolerances, even by 1/64." However, the reevaluation discovered that the statement, "A maximum of 1/8" larger hole than the bolt size i used, is not, and should not have been referred to as being j in QCP-1.42 -2 Revision 4, " Bolt and Gap Inspection for Bolt I Anchor Assembly". Bolt hole tolerances are given on Drawings 47W600 Series (47W600-14 Sec tion "BB" Ceneral Notes and j 47WO61-13A Detail. "E" (bolting size) and 47WO61-1A tolerance for field fabrication). There is only une card to document l 1 final acceptance of the entire panel and this card cannot be uigned until all items are correct. Conclusion i The issue of instrument panels being rejected due to bolting l Lulerances is facLually accuralu, but what it duscribes is not a problem (class B). Although the entire panol was l rejuctud, the only rework necessary was lo rework the i oversized hole. 3.3.16 Issue - Annulus rack piping not inspected for thermal uxpansivn and velsmic movement. (WI-85-027-002) (Site Specific - W8N) Specific Evaluation l This issue was evaluated at WBN. ) i l The following documents were reviewed fur applicability to the i. l issue: QCP-3.13-4, " Instrument Line Interface," Revision 8, i l QCP -3.13 7, " Inspection and Documentation of Sample Line Thennal Flexibility," Revision 0; SCR SCRWBNEEB 8572, Revision 1; NCR 6218; and ECN 6097. 1 -r .r
m v TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 i PAGE 108 0F 144 (' i' Discussion r' i At WBN, QACEG established that QCP-3,13-4, Revision 8, December 24, 1986, and QCP 3.13-7, Revision 0, November 4, 'l r 1986, require thermal expansion and seismic movement I clearance inspections'. Discussions with.QC inspection r' I personnel determined that inspections for thermal expansion 4 and seismic' movement clearances.in the annulus rack of unit i have'not been accomplished to date. The inspection personnel. l stated that this was an oversight. i Discussion with an Instrumentation Engineer indicated that he was fully aware t. hat inspections were not purformed and that re-analysis of radiation sampling and monitoring instrumentation lines would be nocessary. NCR 6218, July 31, 1985, and SCR SCRWBNCEB 8572, Revision 1, February 20, 1986, wure issuud by TVA. ECN 6097 was generated as a result of the SCR identifying approximately 1100 radiation sampling and radiaLion monitoring linos which did not receive adoquate considerations for thermal 6 requirements. The ECN idunlifiud the need to: i I. a. Modify supports and configurations as needed to assuro I \\ adequate thermal qualifications. L b. It, sue calculations to identify sampling lines requiring Lhermal analysis and provide maximum oporating te.maraturo for those lines. i e I' L m 6 er.,* tm e
v g I TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 .I SPECIAL PROGRAM . REVISION NUMBER: 6 l PAGE 109 0F 144 4 i c. Revise and issue drawings per re-analysis. d. Generale project procedures to' define Electrical, Civil and. Mechanical disciplines' thermal interfaco I requirements and responsibilities, i Conclusion 4 The issue that annulus rack piping was not being inspected for thermal expansion and seismic movement is factual and presents a problem for which corrective action has been,-or is being, taken as a result of an employou concern ovaluation (class D). CATD 80214-WBN-02 was issued to the Office of Nucluar Power to track the resolution of the problum, Causos l The cause of annulus rack piping not being inspected for thurmal expansion and weismic movement is a failure to follow j established proceduros. l } Corructive Action l-l Engineering is prosently evaluating affected components as I described in ECN 6007. Re-analysis, calculations, I modifications, issuance of drawings and reinspection is IR6 i schuduled to bu complulud "Before Fuel Load - Unit 1." This I i ,l I corrective action was concurred with by QACEG. Cn fD I l 80214-WBN-02 was issuud lo QualiLy Assurance - WBN Lo track I 1 I the correctivo action, I j l
TVA EMPLOYEE CONCERNS-REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 110 OF 144 3.3.17. Issue - Inspection and Testing of valves numbered 2 -FCV 63-83, -8, -11, -185, -186, 2-FCV-72-40 and 41 f was not performed or was' incomplete before system Lurnover. (IN 85 147-001) (Site Specific - WBN). Specific Evaluation I i This issue was ovaluated at WBN. I I . Discussions were held with personnel from Mechanical Quality Control, Mechanical Engineering Unit, and Quality Engineering and Completion. Discussion MQC, the MEU, and Quality Engineering and Completion stated that t.he valve numberu, au liv Lud, are not all correc t. Valve number 83 is a unit 2 flow control valve on System 62 and should bu listed av 2-FCV 62-83. Valvus 40'and 41 on Syulom 72 are FCVs rather than FCYs (the acronym FCY does not i. exist). Boundary identification maps indicate that the valves fall wiLhin, or on the boundary of Syulem 2-74. This system has f not been turned over and romains within the Construction t Completion Group. Completed inulallation inspection reports uxist for each valvo and each valve has boon included in the ~I sys tem hydros tatic Les t boundary. 9 Conclusion l [ The issue that specific flow control valvo ir.spections and Leutu were not performed was noL' verified as factual (Class A) I Mp a J an e 9 _____________________________m
e e TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE'111 0F 144 3.3.18 Issue -' Required NDE not performed. Weld repair made on Dravo pipe without radiography performod, (PH-85-051-001) (Site Specific'- WBN) Specific Evaluation This issue was evaluated at WBN, The follpwing documents were ruviewed for applicability.to the issue: -General Specification G-29C, Revision 1, " General Welding procedure Specification"; NCR2485; NCR 5512; ASME Material Specification SA-155", Specification for Electric Fusion - Welded Pipe for High-Pressure Servico"; ASME Section III, Subsection ND Sketch 302-6, SH70, 36" ERCW piping. Also held discussions with personnel from Wolding Engineering Unit, Mechanical Engineering Unit and the QA Code Data
- Sectiun, l
Discussion The CI questioned why ground areas'in a 36" ERCW (Unit 2 pipe Lunnei), Dravo uupplied pipe, were repaired without subsequent radiography. Discussions with Welding Engineering Unil, Mechanical Enginauring Units and QA Code Data personnel established that the 36" ERCW, Unit 2 pipe tunnel piping is on sketch 302-6, sheet 78. A' review of the sketch's bill of material revealed that-the piping subassemblies were l fabricated on-s1Le by TVA from pipe supplied by Tube Turns and Progressive Fab, not by Dravo. The piping material is SA155 class 2 which does not require radiography. A review of the repair weld operation sheets for the Unit 2 pipe tunnel piping did not disclosu any wuld repairs in this location as stated by the issue..
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TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM l REVISION NUMBER: 6 r-PAGE 112 OF 144 l Conclusion (-. 1 The issue that requirod'NDE was not performed was not verified as factual '(Class A). ~ 3.3.19 Issue "Information Only" drawings used in the field for ( performing inspections. (EX-85-062-XO2) (Site Specific - WBN) J Specific Evaluation p This issue was evaluated at WBN. QCI-1,60, Revision 1, "Wutk Packagus," was roviowed for applicability tn the issue. Discussions were held with j I Quality Control Civil, Welding Hanger supervision and ) Construction Engineering personnel. { t-l Discussioy QACEG evaluated the issue of inspectors using " Info Only" I + drawings for inspection through discuvuions'with site I personnel. Quality Control Civil, Wolding Hanger I Supervision, and Construction Engineering confirmed that I craft and inspoction personnel had, in the part, utilized IR6 " Info Only" drawings at WBN units 1 and 2. Prior to thu issue of QCI 1.60, inspection personnel obtained an " Info I {' Only" copy of the required drawings for use in thu field. I j j Controlled drawings were located at central locations I t= Lhroughout the plant and were nul working copies. QCI 1.60-l l " Work Packages" was issued March 28, 1986. It revised the I l 4 l 1m 1 ( l L..
m e TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 113 0F 144 previous requirements for control of drawings within the i 1 scope of the procedure. Controlled copies of required' I drawings are now included within each work pack ~ age and IR6 construction, engineering, and inspection personnel have l-direct access to the drawings.within the work package. 1 Conclusion j l The issue is factual and identifies a problem, but correctivo-action for the problem uas initiated before the employee concerns evaluations of the issue was undertaken (class C). Corroclive Action Quality Control Instruction (QCI) 1.60 " Work Packages" was iuuuwd on March 28, 1986. QCI 1.60 eulablishes the method for controlling work and inspection activities and defines responsibilities. QCI 1.60 combined the requirements of the following, superceded, proceduros: QCI-1.07, Revision 12 " Work Release'"; QCI 1.30, Revision 11 " Control of Work Transferred Systems, Equipment, and Architectural Features," QCI 1.56, Revision 10, " Work Packages," and Standard Operating Proceduro (GOP)-09, Revision 1, "Non-QA Work Releave." QCI 1.60 " Work Control" combines the desirable features of the superseded procedures and defines the use of controlled drawings within work packages, eliminating the~use of " Info Only" drawings. .p..
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TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 r-PAGE 114 OF 144 (' l' 3.3.20 Issue - Reject rates are low for Civil Discipline. Civil r-inspuction reject rates are low in comparison to other disciplines. (IN-86-271-001) (Site Specific - WBN) 1 Specific Evaluation l l This luvue was evaluated at WBN. l l l l The following documents wero reviewed for applicability to l Lhu issue: Trund Analyuis reports for April 1985 through November 1985 for all Quality Control discipl'ines. Discussions were held with Civil Quality Control Supervisor. l Discussion Trend analysis reports from April through November 1985'for all QC disciplines were ruviuwed. Thusu reports clearly show the Civil reject rates woro low. However, the August reject percunLage is'luss t.han 0.25 percent lower than the eight month average. The statement that other disciplines show rejuct ratus of over 20 percent at Limeu is not factual. The f highest monthly rate for this period was 14.3 percent, with the uverage for all disciplines falling within the six to ten percent range. A discussion with the QC supervisor was hold and he vlalud that he full comfortable with CQC's reject rate. In the 19 months of CQC's reports studied, t.ho reject l percunlage varlod by less than Lwo purcunt.. I Conclusion The issue that reject ratos are low for the Civil disciplino iu Iactually accurate, but what il describwu is not a problom. (Class B). m o ._--__._.__._________m--_J
e TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL DROGRAM REVISION NUMBER: 6 PAGE 115 0F 144 ) 3.3.21 Issue - Improper measuring methods used during inspection of equipment (W8P c03-002, IN-85-681-001) (Site Specific - W8N) 1 Soucific Evaluation 1 This 'ssue was evaluated at WDN l i j 1 The following documents were reviewed for applicability to I the issue: Specification Number 2529, " Penetration assemblies for WBN unit 1 and 2"; QCP-4.10-15, " Bellows Type Containment Penetration"; NCR 6173. Discussion l A portion of the issue alleged that a Quality Inspector used a ucruwdriver and a rugular fulding r uler to measure uguipment to verify 1/1000 inch diamotor toleranco. QACEG could not perform a meaningful ovaluation due to insufficient information. QACEG reviewed the requirements for fit-up of the containment penetration oxpansion bullows in order to ovaluate the rest of tho issue. The installation and final dimension l requirements are detailed in Specificatlun Number 2529, " Penetration Assemblies for WBN unit 1 and 2," Division of l Engineering Drawings 47W331-1 through 3, and contract Number 83180 drawings P794320D21.1. QCP 4.10 15, " Bellow Type Containment Penetrations" established the method for inspecting and documenting the inutallud configuration and dimenuiunu of the bullowu assembly. ' i l i
TVA EMPLOYEE CONCERNS REPORT NUMBER:.80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 116 0F 144 (~ QCP-4.10-15 required that measurements be taken to verify thac the insLalled bellows lungth be within the Lolerance i shown on the contract drawing. t [ Additionally, the QCP required measurements to verify that the bellows ribs were aligned to the dimensional tolerances f shown on the engineering drawings. Drawing 47W331-3 required that field measurements have a tolerance'of plus or minus~1/8 { inch. Discussions with the Construction Mechanical Engineer and the Mechanical Inspector who took the measurements revealed that a folding rulur graduated in 1/16 inch increments was used to measure the overall bellows length. A stuel rule graduated to 1/64 inch was used to check thu bellows alignment. These meas,uring devices would provide the degreu of accuracy required for the field measurements. The QCP stated that standard, uncalibrated measuring devices such au Lapes, rules, and scales could be used for inspection. The Topical Report, TVA-TR-75-1A, allows the use of commercial quality rulers, Lape measures, levels,. and similar
- devices, It is noted that NCR 6173, Revision 0, was issued I
on July 9, 1985, vince eight of the bellows woru out of alignment due to removing the shipping bars prior to inslalling the asswmblies. Engineering disposition was provided on October 17, 1985. After installation, the alignmenL of the bellows avvembly again changed due to I welding shrinkage. Revision 1 to NCR 6173 was initiated on October 23, 1985 to document this misalignment. The NCR is still in the disposition process. / l l 1 1 ( L. L _m._
l l s TVA EMPLOYEE' CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 117 OF 144 Conclusion r The issue that improper measuring methods were used was not verified as face.ual (Class A). The measurements were l performed utilizing measuring devices of sufficient 1 accuracy..The measuremenLu were.taken and documented in aCCordance With the procedural requirements. q I l l l 3.3.22 Issue - HVAC duct support inspections were performed prior to ) ) l the issuance of the design drawings. (IN-85-469-X05) (Site Specific WBN) Specific Evaluation This invue was evalualed at W8N. The following documents were. reviewed for applicability to the issue: Construction Specification N3M-914, Revision 2, " Quality Assurance Requirements for Construction, Cons truel.iun Tes ting, Inspuc Lion Tes ting, and Inspection 'of Safety-Related HVAC Systems"; WBNP-QCP-4.23-8, Revision 9, " Support Final Inspect. ion"; and Fiuld Change Requust A-10575. Discussion The CI identified two specific HVAC duct supports (20300W920 -10H-1085 and 20300W920-10H-1087) as being inspected before issuance of drawing 47W920-10H, Revision 0, September 27, 1002. I _ _______ n- _mcr 1_ 1 __.z-:r 1- -=_ __ 1 ___ _
TVA EMPLOYEE CONCERNS REPORT NUFsER: 80iau SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 110 0F 144 r Inspection records show that HVAC support 2030DW920-10H-1087 wau final inspected on July 7, 1982, which is before Design 1 r-Drawing 47W920-10H, Revision 0 was approved and' issued. Final inspection was documented in accordance with QCP-4.23, Revision 2, " Final Inspection of Fe:smic Supports." No records were available that document inspections of HVAC support 20300W920-10H-1085 before design drawing issuance. FCR A -10575 was issued Noveinber 27, 1985, to change HVAC { support 2030DW920-10H-1085 from a 47A055-17 (Category I) to a 470055 -189 (Category I-L) type support which af fects drawing 47W920-10H, Revision 2. Inspection records show that this support was inspected and accepted on December 17, 1985, in accordance with QCP-4.23-8, " Support Final Inspection," and { l after issuance of the design drawing. Howuver, no inspection l was performed for the procedural requirements of QCP-4.23-3, " Support Location and Verification," regarding location and configuration. 1 Conclusion t The issuo that HVAC duct supports were inspected bofore isuuance of design drawing was found factual in one caso and } presents a problem for which corrective action has been, or is being, Wken as a result of an employee concurns evaluation (Class D). Support (1087) was inspocted and accepted before drawing luvuanco and no evidence exists that l the actual configuration of the support ' matches the design d rawi ng. Support (1085) did not have location and f orientation verification inspection performed as required by i QCP 4.23-3. . I. t. I'
TVA EMPLOVEE CONCERNS REPORT NUMBER: 80200 i SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 119 0F 144 i 1 Causos The cause of HVAC duct support inspections being performed prior to the issuance of the design drawings results is a failure to follow established procedure requirements for final inspection of duct supports. Corrective Action As a result of HVAC support 2030DW920-10H-1087 having been ] final inspected before the approval of des' drawins 47W920-10-H, Revision 0, Quality Ass nce - BN has replied Lhat before the issue of the de r rawing a i ' eld generated drawing 47W920-10-H contro w' issuod. It was to this drawing that L.he ir; pport 2030DW920-10H-10 et )b I -7, " Support Final Inspoulion." v isla Lo show that io eji locat' a itatiop rified in accordance with Su t on and verification." Quality A M o ed the corrective action which is to ins ucL and do-ient the location and orientation of this su ppo'.t. I-16 will be used in lieu of QCP-4.23-3, since this is the applicable procudure for transferred supports. This responds to CATD 80214-WBN-01 and has been concurred with by QACEG. 3.3.23 Issue - Inspectors are not consistent in interpreting es tablished acceptance criteria. (EX-85-056-001, IN-85-057-001, IN-86-133-003, IN-86-284-001, OW-85 004 001) (Site Specific - W8N) -. mas, ao e
+ TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 ? PAGE 120 0F 144 f Specific Evaluation r This issue was evaluated at WBN. 7 The following documents were reviewed for applicability to Lhe issue: Quality Training Program Manual, "Oivision of~ .j Construction, Quality Training Program Manual"; PQA-SIL-4.2, " Quality Control' Inspection and Monitoring' Program"; QTC ERT' l Investigation Reports, EX-85-056-001, IN-85-057-001, f OW-85 004-001, NRC 6850; QCP 2.12, " Protective Coatings Inspection." Discussions were held with a Quality Control Welding inspector. Discussion Discussions with a Quality Control welding inspector indicated that the interpretation of the allowablu amount of overwolding had changed. The inspection of hanger wolds had pruviously buen performed by Quality Control hunger inspectors. The critoria had not changed but this group had nul allowed for fil up in their inupucLion. Thu following example clarifies this discussion: A hanger is Lv be connected t.o an umbedmunt plata. The required wold leg sizo is 1/4 inch. There-is a fit-up gap vf 1/8 inch por design drawing 47A050-IN, Gonoral Note 50. The wold log may be a maximum of 100% 6' oversized. The banque inspector allowed a maximum 1/2 inch weld 109 The weldinq inspector allowed a maximum i 5/8 inch weld leg Lo compunvale for the allowable fit-up gap. I (Note: The inspections by the hanger group woro more t stringent than required in this example). L e
~ g TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 121 0F 144 QACEG evaluation of three NCRs generated to document numerous welding deficiencies indicated that the visual welding inspection had not been adequate. NCR 2019 rev4alud that 24 seismic pipe supports had been reinspected during a training session for new field inspectors, The existing welds were found to be defective. These welds had previously been inspected to the requirements' of QCP 4,8, " Inspection and Documentation Requirements for Mechanical Supports,"~ QCP-4,23, " Installation Inspection and ) Occumentation Requirements for Seismic Pipe Supports" was issued on February 8, 1980. The inspection personnel were l retrained to the procedural requirements of QCP-4.23 and all i seismic pipe support welds were reinspected. QCP 4,23 has been replaced with six QCPs Lu give a better bruukdown of the attributes to be inspected for solsmic pipe supports. QCP-4.23 4, " Visual Examination of Support Weld Joints" was issued on May 16, 1983, to further segregato the welding aLLributes for seismic pipe supports, NCR 2111 was issued on February 21, 1980, to document j deficiencies with piping socket fillet welds,. As a rusult of the NCR, all ASME welds on 478001 supports accepted prior to September 29, 1980, were reinspec Led. All ASME branch connection welds accepted prior to August 15, 1980, and all other ASME fillet welds accepted prior lo April 1, 1980 were reinspected. Additionally, as of Apr il 1, 1980, all wolding inspeeLors were retrained-in the accuptance criteria for fillet welds, As of August 15, 1980, all welding inspectors were retrained in branch connecLlon wuld criteria, and as of September 29, 1980, all welding inspectors were trained in Lhe 47 0001 support critoria, ,b n
- s-v 1 TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 I SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 122 OF 144 NCR 2375 was issued on June 11, 1980, to document weld a deficiencies for cable tray supports, conduit supports, and miscellaneous steel. The Welding Engineering personnel were retrained in inspecting fillet welds and mechanical gages f' were provided for visual inspections. l A detallud discussion on inconsistent protective coating inspections is contained in Section 3.2.9 of this roport. l The diucussion in that-section states that there were different interpretations of the allowablo deviations from the specified dry film thickness. QACEG evaluated other inspection documents to determine if adequale and consis tunt ins tructions were provided for non wolding disciplines. Division of Engineering Design drawings that wer e reviewed pr ovided aduquale implementation notes and cross-references to specific'ations and othur drawings. Sufficient dimensions and details were prusunL so that thu amount of drawing interpretation would be minimized. The 1 QCPs and QCIs that were reviuwod pr ovidud detailed inspection f attributes with quantitative data where appropriate. The QCPs spelled out L,he inspuc tion r equir emunLs in lieu of referring to codes or other documents for the inspection critoria. l Revisionu of QCPs were reviuwud 'for the Lime period of July, 1982, to present. Historically, the procedures have improved with rugard to clarily unJ pe oviding a more conciso breakdown of the attributes to be inspectod. Older revisions tended to lump Lhe altributes in a paragraph format. Orton times thu older revisions would refer to other procedures or specifications for the accept /r ejuct crituria. i
t ~ l TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM. REVISION NUMBER: 6 I PAGE 123 0F 144 l l 1 Conclusion The issue that Inspectors were not' consistent in interpreting 1 - established acceptance criteria 1u factual for visual weld IR6 ~ inspection and coating inspection. Corrective action was I initiated before the -employee concerns evaluation of the issue was undertaken (Class C). QACEG ovaluation did not find evidence of inconslutent inspections in other areas of work. ) Causes ) The cause of Inspectors not being consistent in interpreting i established accuplance criturla can be aLLributable to a lack I I of clearly defined procedural requirements, especially I acceptance criteria. The lack of Lraining for the personnel IR6 I responsible for executing the requirements and an inoffectivo 1 procedure ruviow sys Lem were cont.ributing, i Currective Action NCRs 2019. 2111, & 2375 woro issued in 1980.to document welding deficiencies idenLified.during the visual reinspection of the installed work. Reinspection of cable Lray supporLs, conduil supports, miscellaneous steel, piping sockets, and seismic pipo supports woro documented 'during the ficul half of 1980. CurrecLive acLivns Laken at that time i for inconsistent visual weld inspections wore as follows: Revision of implementing procedures to provido more ) a. explicit accept / reject critoria. J +# 1. ~. '~~~'# " ~ ~ ' " * ^
m o-i TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 l SPECIAL PROGRAM l REVISION NUMBER: 6 ~* PAGE 124 0F-144. i. b. Retraining of welding inspection personnel to the visual q welding inspection criteria. j ~' 4 c. Measuring gages were provided to'the inspection personnel'. ) A review of the overall welding program at WBN was instituted - 1 by TVA in 1986. EG&G, a DOE contractor, has been performing I 6. reinspection of welds and a Welding Task Group has boon IR6 f' evaluating welding issues. Separate reports will be issued I l by the respective groups. I r i NCR 6850 was issued to document the improper use of Allachment A, " Allowable Deviatiuns from Specified Dry Film Thickress (MILS)," to QCP-2.12, "Protectivo Coatings Inspections." i 3.3.24 Issue - Employees initialing checklists without performing work. (IN 85-954-001) (Site Specific - WGN) 4 Specific Evaluation f This issue was evaluated at WBN. Employee Responso Team I (ERT) Report IN 85-954-001 wau ruviuwod and a discussion was held with the Chief of Security - WDN Public Safety Servico (PSS). Discussion QACEG interviewed the Chief of Security - WON PSS who i confirmed that the issue involved PSS employees initialing checklists without performing the work. As reported in ERT a I.- l
t o e TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBERt 6 PAGE 125 0F 144 Report IN-85-954-001 this issue has no relation to activities affecting the quality of plant construction. In addition, the issue has been evaluated by the Intimidations and Harassment Group and is listed in report 60300. 1 Conclusion The issue of employees initialing checklists without performing the work was not verified as factual.by QACEG (Class A). 3.3.25 Issue - Field Inspectors inspect to procedures. They don't use common sense. (EX-85-064-004; (Site Specific -- W8N) Specific Evaluation ( i This issue was evaluated at W8N. QTC Report EX-85-064-004 ] and Apperidix B to 10 CFR 50 were reviewed for applicability { to the issue, i l 4 Discussion Criteria V of Appendix 8 to 10 CFR 50 states, in part, that j " activities affecting quality shall be prescribed by documented instructions, procedures, or drawings...and shall a be accomplished in accordance with these instructions, procedures, or drawings. Instructions, procedures, or 1 drawings shall include... acceptance criteria..." Field ] + Quality Control Inspectors are trained in the use of j procedures and are required to base their inspections on the guidelines documented within these procedures. l ) l i ___r__ I
e TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM r, REVISION NUMBER: 6-pAGE 126 OF 144 Conclusion p. { The issue that Field' inspectors inspect to procedures is factually accurale, but what il dever ibes is not a problem (class B). Inspectors do utilize procedures during the i inspection process and this practice is uncouraged. Because I" the meaning of " common sense" in this context could not be i I I" specifically defined, this ' portion of the issue was not IR6 r evaluated. I t l 3.2.26 Issue - QC inupecLion is inaduquale (WI-85-100 033) (Situ i Specific - WBN) l r l Spocific Evaluation l This issue was evaluated at WBN. i QACEG evaluation consistud of discussions with Instrumentation, Civil, Welding, and Electrical Quality j t Control Gupurvision. Thu discussions were hold for tho i purpose of gaining information relevant to this issue, and l 1 establishing the requiremenLu for Lho af feclud Qualit,y Control organization. I' Discussion i 6 4 l The CI was nonspecific as to an area of concern, i.e. l Welding, Instrumentations, Hangers, HVAC, Piping, ute, Therefore, QACEG could not perform a proper evaluation of tho luvue itself. However, several programu have beun initiated for reinspection at WBN. Many of thesu programs have boon institulud av a par Llal ruuult of inadequato inspections. Le
j i TVA EMPLOYEE CONCERNS REPORT NUMBER:. 80200 . f SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 127 0F 144 I 1 Conclusion 1 1 The issue that QC inspections were inadequate in some areas ] is factual and identifies a problem, but corrective action for the problem was initiated'before the employeo concerns evaluation of the issue was'unductaken (Class C). Numerous reinspection activities have been undertaken as a result'of employee concerns and other TVA initiatives, 1 i Causes The cause of QC inspections being inadequate stems from i i managements railure lo implement adequate. programs to I facilitate inspections with clearly and completely defined IR6 requiremenLu and acceptance criteria. I l Corrective Action As a partial result of inspections being inadequate, TVA has I instituted reinupaction in a number of areas. Examples I include the Hanger Analysis and Updato Program, the Conduit l l l l l and Supports Reinspec tion Program, Lhe Plant Welding Program, I R6-and the Instrumentation Project. The Engineering and I l Construction Assessment Program contains a commitment to I -l perform a reevaluation of the results when the work is I completed. I 1 3.3.27 Issue - Inadequate Installation of Conax Connectors, l Conax corinactor u in the cotilairiment did not always meet vendor wire bend radius instructions, connector installations with deficiencies were inspected and accuptud by Sequoyah l l l 4
n-TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM-REVISION NUMBER: 6 l PAGE 128 0F 144 r t l-Quality Control (SQN QC); no action was'taken by SQN QC management to investigate or document the deficiencies. cs t' (I-86-101-SQN) (Site Specific SQN) Specific Evaluation f' This issue was evaluated at SQN. i~ The following documents were reviewed for applicability to i the issue: NSRS I-86-101-SQN, " Installation of Conax Connectoru"; Corructive Action Ruports SQCAR 86-02-005; M&AI-19, " Installation of Conax Connectors," Revision 1; and Conax Vondor Manual, Ruvision G, IPS-725. Discussion Tho issue dealing with Conax-connectors was the subject of NSRS report " Installation of Conax Connectors," I-06-101-SQN, j j February 1986, and a Correctivo Action Report (CAR) SQ CAR 06-02-005, February 10, 1986.. Two moLor =vpuratud' valvus wuro } verified by the NSRS to have wiro bend radii below minimum allowed. A vamplu was thun Lukun from unit 1 and 2 which lJ revealed an additional 14 instances of deficient wiro bond l radii. Workplanu wure wrillwn lo install the connecturs, l*. field installation was completed and inspoetions woro I \\. performed. Prior workplans did nol contain stops to verify 1 wire bend radius, nor did they reference the vendor manual i for installation requirements, j u } t i j L. l 1.
m e l l TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 I PAGE 129 0F 144 QACEG reviewed the corrective actions associ.ated with CAR-85-02-005. M&AI-19, " Installation of Conax Connectors," was revised to include" installation criteria and inspection requirements for wire bend radii and to incorporate a reference to the Conax vendor. manual to ensure proper torquing and application of the Grafoil sealant that'is used in these connectors. A 100%. reinspection of'.all Conax connectors was performed and rework was accomplished as necessary. TVA QA verified that proper corrective action.was taken and CAR--86-02-005 was closed in August 1986. Conclusion ) The issue that r.onnectors'were installed, inspected and I accepted by QC Lhat contained deficiencies is factual ~uince I Lhere were cases found where wire bend radii wore i unsatiuract.ory. Work plans for 1,he installation of the IR6 connectors did not address bond radii when issued nor did l Cuneral Construction Specification C-38. Corrective action l for the problem was initiated'before'the employoe concerns uvaluallon of the issue was undertaken (Class C). Investigation revealed that Conax connectors that did not meet the vendor wire bund radius ins tructions: had been installed in the containment. However, this condition was documentud in SQ CAR 86 02-005, reinspection were performed, and corrective action was completed. f i .h
n ~. t' l TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 .PAGE 130 0F 144 g k The issue that no action was taken by SQN QC Management to e investigate and document the deficiencies prior to the NSRS I investigation was substantiated. No information was found to determine whether anyone knew there were deficiencies prior .i to the NSRS investigation, Cause f The cause of inadequate installation of Conax connectors is: a I failure to incorporate manufacturers ins truc tions for correct IR6 methods for installing and inspecting the connectors in the l f specification and/or workplans. I Corrective Action i Correctivo Action Roport CAR-86-02-005 was' issued in February 1986 to document that Conax connectors were installed outsido of allowablo limits. Corrective actions included Environmental Qualification (EQ) reviuw and concurrence with the Conax Vondor Manual and issuance of Revision 1 to i Maintenance and Addition Ins truction M&AI-19 to include wiro 7 bend radii criteria, Rework and reinspection were performed [, on all Conax connectors and verification by Quality Assurance (QA) was completed in August 1986. No further action is
- required, 3,3,28 Issuo - Piping Inspections Not Performed.
Non-code piping and heat. exchanger welds' not inspected for acceptability (XX-85-007-003; SQM-86-009-001) (Site Spocific - GQN)
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m e e. TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 131 OF 144 Specific Evaluation This issue was uvaluated at SQN. l CAQR SQP-870565, Revision 0, Non-Critical / Critical Systems LisLing, Appendix A of SQo 134 and Inspection reports of non-CSSC systems were reviewed. for applicability to the issue. Discussion The portion of the issue regarding heat exchanger welds was l I not initially evaluated as specific information was not I available for a meaningful investigation, The NRC provided IR6 additional expurgalod information lo QACEG. I The additional information specified " welds on heat 4 uxchangars A, B, and C for the component cooling water system, located in the Auxiliary Building, at elevation 714 " " Finding numerous linear indications in vendor welds on the support pads. QACEG's evaluation revealud that previous corrective' action ' l l had taken place. Magnetic particle examination (MT) reports ' ] of the cooling water heat exchangers "A," "B," and "C" 1 (serial number 6721, 6722, and 6723) provided objective { evidunce that welds with linear indications had buen ground 1 l and re-examined to satisfy requirements. l' l s w t uw_______2______.-_._
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 I SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 132 0F 144 I 'l Another portion of.the issue pertains to non-code piping not receiving quality inspections. A review of the Non-Critical / i 6 indicated l Critical Systems Listing, Appendix A of SQA-134, l that the condensate System, Heater Drains and Vents System, and portions of the Feedwater and Auxiliary Feedwater Systems, given as examples in the concern, were determined to j j be non-safety related and were not subject to the provisions of the TVA QA inspection program. However, these systems are inspected on a random basis by the foreman or construction l l craf t personnel, or both. For those portions of the Feedwater and Auxiliary Feedwater System which are considered critical, a ruview of the serius 47W803 flow diagrams further revealed that complete piping / welding inspections are required and have boon completed. Inspection reports of l non-CSSC systems were also reviewed, indicating that informal inspections were perfunned by construction on randomly selected welds. This further substantiates the fact that l l uven though the systems du not rwquire formal inspections by QC, they were inspected by the foreman or construction craf t i pursonnel, or both, un a randum basis. a Conclusion f l { j This issue was not verified as factual (class A). l f,- ) s. 3.3.29 Issue - Anchor Pull test results falsified.by craft and inspection personnel (XX-85-023-XO2) (Site Specific - SQN) i I i Specific Evaluation t [, This issue was evaluated at SQN. L L
g TVA EMPLOYEE CONCERNS REPORT. NUMBER: ; 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE'133 OF 144 The following documents were reviewed for applicability.to the issue: -QTC Report XX-85-023-XO2; General Construction Specification G-32, Revision.4 and 5, " Dolt anchor set in hardened Concrete." Discussions were held with Civil-QC~ inspection supervisor and inspectors. Discussion A SQN Inspection supervisor provided.the names'of five inspecLion personnel who were involved in anchor bolt i inspections in 1977. These personnel.were interviewed to determine their knowledge of falsification of Lest records or other wrongdoing. None could recall any instances of falsification of test results at GQN. l j. The QTC report mentioned conducting interviews.with 27 individuals involved in the installation and inspection of anchor bolts. The individuals denied knowledge of falsification of Lust records. The Office of General Counsel (OGC), in its memorandum (RIMS A02860501006) to the Manager of Nuclear Power of April 30, 1986, concluded that in its review of the QTC investigation into the issue o? craft and inspect.iun personnel falsifying anchor pull tests and documentation there was ". .no collaborating / objective- / uvidence found to allow subs tantiation. ' The OGC will Lake no further action on this issue." In a phone conversal.iun.with the Of fice of L.he Manager of Nuclear Power, ONP advised that it has accepted the decision. of the OGC regarding this issue. The COCEG has performed an extensive investigation and ovaluation of anchor issues.and has reported their findings in Subcategory Report 11300, Revision O. 4 m 9 e a s. e = - .__h.- __.__-__._m.____n-.__--.-h
v-. TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: '6 1 PAGE 134 0F 144 f.. I Conclusion- . (. g-1 Based on interviews,' lack of data toisupport the issuo,.the ERT Report and the OCG memorandum, it is concluded that the issue of craft and inspection personnel falsifying anchor pull tests and applicable documents is not. substantiated (Class A), 3.3.30 Issue - Reinspected items.are inspected by less qualified personnel. (XX-85-069-008)'(Site Specific - BFN) Specific Evaluation This issue was uvaluated at BFN. No additional information was derived from'the Employeo Concern File or the Confidential File, nor could ony plant documentation be found pertaining to this issuo. Discussions were held with cognizant GFN Quality Control' supervisors from difforent disciplines, Discussion i ~. Regardless of ' experience or qualifications,'all personnel f l performing inspecLlons or reinspection are certified in L. i accordance with specific procedures. Due to.the lack of spucific information provided, discussions wuro held with QC and Maintenance supervisors from mechanical and electrical disciplines at BFN, and although they agrued that such a (, thing could possibly have happened, it would not have boon inLonLiunal. 7 i
1 j TVA EMPLOYEE CONCERNS REPORT NUMBER: 80300 SPECIAL PROGRAM 1 REVISION NUMBER: -6 I i i PAGE 135 0F 144 i They further explained that it is the standard policy for I rejected ILems to be reinspected by the initial inspector and d that reject forms include specific information as to the naLure of the discrepancy. This practice assures that if it ~ becomes necessary to' involve a second inspector he would be aware of Lhe initial condition of the item. ' Conclusion ? The issue of reinspected items being inspected by less qualified persortnel was not verified as factual. (Class A) l 3.3.31 Issue - Hydro test packages not properly filled out and reviewed. Ins trument Hydro packages did not contain a listing of the respective valves on the valve line up sheets. ASME III piping Hydro's are not being signed by the ANI. (IN-86-288-001, XX-85-068-002) (Gile Specific - BLN) j l 1 j Specific Evaluation l Thlu issue was uvaluated at WBN and BLN. l I The following documents were reviewed for applicability to Lhe issue: QCT-3.13, Revision 5, "HydroslaLie Pressure Testing of Instrumentation Sensing Lines"; BFN-CTP-7,6, "flydros taLic Tes ting"; and BNP CTP-4.14, " Flushing and Pressure Testing of Instrument Lines"; Hydrostatic Test Packages. Olucussions were hvid with Mechanical Engineering personnel, Construction Engineering personnel, MQC personnel, and the ANI at BLN in relation Lo hydro-test packagu preparation, review approval, and final test approval processeU. 3 u g$ waA
_y-- TVA EMPLOYEE CONCERNS REPORT NUMBER: 00200 SPECIAL PROGRAM REVISION NUMBER: 6 !s l PAGE 136 OF 144 I l Discussion i -l At WBN a review was performed of QCT-3.13, Revision 5, ) " Hydrostatic Pressure Testing of Instrumentation Sensing l Lines," and QCT-3.14, Revision 3, " Flushing of Ins trumentation Sensing Lines." It is a requirement of both test procedures to list the respective valves within each tout boundary and whether they are open or closed during the O [ test. A thorough review of 30 Hydro-Test and Flushing Test j pac!: ages revealed that this requirement is being met, fhe review was a matchup of test boundary drawings against tho l valve line up sheets and a verification that the valves were l listed with open/ closed position correctly shown. At ?LN, in accordance wiLh BNP-CTP -7.6, " Hydros tatic Tes ting" and BNP-CTP-4.14, " Flushing and Pressure Testing of i Instrument Lines," the Mechanical Engineering and Instrumentation Engineering Units are responsible for assigning appropriate engineering and QC inspection / verification steps according to Lho requirements of specifications and drawings. As of October 30, 1984, Lho Division of Nuclear Engineering had compiled a listing which i idontified those syulemu, strucLuros, and components that l l were within the scopo of the QA Program. This listing is } 'I referred to as the "Qualit) Assurance Livl (Q-List)." Within 1 i I this list are components that require full QA inspection, limited QA'inspeelion av describuo in N40-889, " Identification of Structures, Systems, and Components Covered By The Bellefonte Nuclear Quality Asuuranco Program," and those components that do not require any QA inspection. I IL f l t
se u .TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 137 GF 144 1 The listing is used in addition to design. criteria as .j a contained in specifications, design criteria diagrams, and 4 drawings. QACEG reviewed the actual flow of a typical hydro Lest' package for ASME III systems as issued by Mechanical and Instrumentation Engineering, which had full QC and ANI i 'I involvement. i Forty-three hydrostatic test packages, prepared and l controlled by MEU and IEU, were reviewed. The intent of this review was to determine the extent of involvement by QC and the ANI, including.the reviuw cycle of the hydrostatic test I package. Of the 43 hydro packages reviewed, one had not been reviuwed by QC since il was a non-QA hydro and six had not l been witnessed and reviewed by the ANI since they were not ASME III systemc. All other packages were reviewed by QC l before hydres were performed. Hydro inspections wero l verified, witnessed, and accepted by QC for thu requirod steps as designated by Engineering. Also,- QC certified that the iaul was acceptable, in accordance with GNP-CTP-7.6 l requirements, and that the ANI had witnessed and accepted the hydro. The Quality Manager had apprvved Lho hydrostatic tout packages. All of these reviews and signatures were dated in a chronological order. However, inconsistencies were found pertaining to the dates the QC inspector witnessed the hydro l-und the ANI witnessed the hydro. Tho Mechanical Engineer ] clarified this inconsistency by stating that this portion of ) the test package was actually the date of ruview of the Lost package itself and not the actual date the hydro was witneuvud by the QC Inspector and the ANI. The actual dates of inspection and witnessing are found on the " Sign-off i)LLuchmunL" sheet next to the respectivu step number assigned to the QC inspector and the ANI. w 96 h' .__-__.-._...____-__._._Q
TVA EMPLOYEE CONCERNS rep 0RT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 130 0F 144 Even though it is a requirement of ASME Section III for the ANI Lo witneus all " Code" hydros, it is not a proceduralleed requirement of BNP-CTP-7.6 to include an entry for the ANI into the " Sign-of f AttaOment. " Engineering has from time to f { time entered a step number for the ANI to sign when he witneused a hydro, but Lhere are hydros where that provision had not been made. Because of the inconsistency, it appears )' that the ANI is witnessinq and accepting the hydro on a ~ different date than when the QC inspector witnesses and l accopts the hydro. 1 IEU process their hydros in a similar manner as the MEU. The same inconsistent.es were evidunt as far as the dato the ANI actually witnessed the hydros. Of the 11 hydro packages reviewed, one had the ANI's signature and dato noting Lho actual verification dato of the hydro by the ANI. The IEU, based on the suggeullon of the ANI, has added a separate signature line for the ANI to Attachment E, of UNP-CTP-4.4, I Revision 3, OcLober 30, 1986 " Hydros tatic Tes t Proceduro," IR6 for all future hydros. Because of the discrepancy boLween l l Lhe dates of Lhe witnessing of the Lust by Lhu QC Inspector and the ANI, QACEG verified with the ANI, using his daily log { book, Lhe acLual dates he witneused the Luut to assuro Lhut it was the same day as the QC inspector. One Instrumentation f packagu (1KECl-H 003), documenting a hydro for 1IX-ILPK-008A-B, could not be verified using the ANI log book, t, Furthur research revealud that this lino had buen pruviously tested and documented in 1KEC1-H-001. It was documented in Soquence Fontrol Chart SCC #1-KE-I202 that some rework had been performed to lIX-ILPK-0000. QACEG reviewed 1KEC1-001 and verified that the ANI did witness Lho test for IIX-ILPK-008 A and D at the same timo as tho QC inspector. i l L_ 1 s ee) D DM*% # W l
l 1 TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 i SPECIAL PROGRAM I .'.EVISION NUMBER: 6 PAGE 139 OF 144 a 1 i Conclusion The issue of Hydro test packages not properly filled out and reviewed does not identify a problem (Class A), but as a result of the employee concerns evaluation a problem was discovered for which corrective action was initiated. ) 1 BNP-CTP-7.6 was never revised to incorporate an entry on the j " Sign of f attachment: for the ANI to sign that the hydro was j witnessed. 3 Causes The cause of potentially confusing Hydro test packages was a i failure to provide a signature block for the ANI attesting IR6 Lhat he witnessed the hydro test. 1 Corrective Action I Construction Enginaring has stated that nmo m if be ,,v reviuod to ir"-1-E - awparate T9 r the ANI whichk g 1 t the ANI actuall .4 MeTses the ost. $n jdtf ian, final AMI ) r signatus e'line ggyi - .-, aa, " T n = +- "r-u Acceptec Thie _ _,,,,,u a to CATO 80221-BLN-01 and has been concurred with by QACEG. 3.4 Inspection Responsiveness 3.4.1 Issue - Untimely response by QC personnel to requests from craf t to perfor m inspections. (IN-85-203-001, IN-85-301-001, IN-85-359-001, IN-85-372-003, IN 05 423 002, IN-85 596-003, IN-06-115-003, WBN-253, IN-85-596-004) (Gite-specific-WON) s
~. ~ TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 i PAGE.140 0F 144 i Spoeffic Evaluation I This issue was ovaluated at WBN. 4 The following documents were reviewed for applicability to Lhe issue: QAPP-10, Revision 3, " Inspection"; QCI-1.02-1, l Revision 10, " Inspection Rejection Notices"; QCI-1.60, l l I Revision 1, " Work Control"; QCP-4.23, Revision 5, " Visual ( Examination of Support Weld Joints"; QCP-4.13-FU & VC, Revision 5, "Fitup and Visual Civil"; QCP-4.23-8, Revision 9, l " Support Final Inspection." Discussions woro hold with'a-Hanger Inspection Group Leader, QC and Craf t personnel. I Discussion 1 1 l Writton requirements delineating QC response time, to rwquosLs for inspection, do not exis t. Thorufore, it was j necessary to rely on information gained from discussions with I l individuals involvud during the Lime period of the issue, and l on informal " response to employee concern" reports found in the Employee Concern File. QACEC concludud that QC rosponsu lime for inspection requests was excessively long at times for various reasonu, including priority of assignments, unexpected absences, shortages of calibrated tools, and l shortages of qualified inspectors during periods of peak demand. In addition, QC and craft personnel stated that, in the past, IRNs had buen initialud for workers not being at i .i the scene when the inspector arrived which adversely affected IR6 working relationships. I l e d l ) .a' 1
] o i TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM -1 REVISION NUMBER: 6 PAGE 141 0F 144 Information gained from the various discussions was consistent with the documentation examined. During an interview, a Hanger Inspection Group Leader commented (paraphrase): "There were a couple of QC Hanger Inspectors j deliberately dragging.their feet, but this problem was ] identified 'and appropriate corrective action was Laken." J k Similar information is detailed in the response section of Concern Dispoullion Report IN-05-263 003: "Rocords do indicate that there have been occasions that shop craft personnul have waited uevwral hours for a wolding inspector." Results of discussions and respective documentation reviewed ~ i in the Employeu Concern File, indicale delays waru encountered 1 by the craft personnel, but they had no impact on tbo' quality of the work. 1 J Also, Employee Concern Disposition Roport 05-23-002 states: j "The condillon described in the concurn occurred in the past, _ but steps have been taken to provent recurronce." ) A random sample of thirty -Lwo weld logs, encompassing an eight-month period in 1986, were reviewed to determino if this acknowledged problem was being addressed.. It indicated same-day responses for all inspection requests and reasonably prompt responsu Limuu in guneral (luus than one hour). No incidences of delayed or excessive response times wore noted within Lhw sample reviuwed. 5 4 - - - - - - - - = - - - - -
1 TVA EMPLOYEE CONCERNS ' REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 16 PAGE 142 0F 144 1 l . p I . l. Conclusion I' The issue of untimely response by QC personnel to requests 1 1 from 'craf t for inspecLors is factual and identifius a 1 problem, but corrective action for the problem was initiated before the amployee concerns. evalualiun of the issue was undertaken (class C). l Results of previously identified discussions and documentation reviews clearly indicate a general concurrence 1.hroughout the QC DecarLment that't.here were problems with inspection response times for various periods in 1985 and 1986. It is under s tood that -inspection units are not staf fed for peak demand or instant response to inspect completed work. Becauue the timelineus of inspection has no impact on j the quality of the weld, thoro is no impact on the acceptability of the hardwaru. l Cause l The cause of untimely response by QC personnel to requests from cr af L Lv perform inspe61.ionu is a reuull of i iadequale resources and poor planning and communication bolween craft and inspection peruunnel. ? Correctivo Action (' l In order to track inspection roquest times versus response Limeu, the QA Department duveloped an Inspuction Ruquest Weld i i Log for general use by both craf t and QC. The log documents the L.ime of requesL, by whom, location, QC Inspector j time-out, and time returned. The log serves as an historical l 1 lE____._______._
e TVA_ EMPLOYEE CONCERNS REPORT NUMBER: 80200 SPECIAL PROGRAM REVISION NUMBER: 6 PAGE 143 OF 144 record of response times and is used to aid in making IR6 l improvements in planning and schuduling. It alun serves to-1 1 . eliminate charges by. both craf t and QC regarding slow I response time. The Inspection Roquest Log is only usud by Lhe Hanger Weld group because it is only'in this area that inspector responsiveness was determined to be a pr oblem; Review of this log indicates that there have been reasonable response times to requeuls for inspections. However, because the present (1986-1987) rate cf construction is much slower than when the concern was raised, Lhe review may be somewhat. restricted due to the reduced number of requests for inspections. NSRS Dispositions Report number IN-85-8359-001 states in the closure statement," The Quality Manager Ortjanization has commilled Lo perform all inspections'in a Limely manner, l 4.0 COLLECTIVE SIGNIFICANCE l The deficiencies identified in this subcategory have contributed to some I of the significant problems currently being uddressed and resolved by 1 TVA. Examples include cable installation at WBN, welding, and l instrumentation. Because TVA's inspection procedures did not' fully I implement regulatory and design requirements and TVA commitments and in I some cases did not keup pace with the evolution of nuclear industry IR6 practices, substantial reinspection and reverification programs are'now I i required. Individually, Lhe impact of deficiencies in the inspection I . 1 program varies. Some have had no impact, others have contributed to the need for subulanLidl hardware rework, repair, and replacement, and some I resulted in questions regarding the capabilities of inspection personnel. I .o f 'I i J + = = - * *ry- ..__.___________E_U
TVA EMPLOYEE CONCERNS REPORT NUMBER: 80200- .SPECIAL. PROGRAM.- REVISION NUMBER:6 ~' PAGE 144 0F.144 [. 5.0 ATTACHMENTS ^ Attachment A " Subcategory Sununary Table.and List of' Concerns." - '"Llu t of CATDs isuuwd," I 1 . 2 j ' 1 I . i ' i i l I s. l 't L. 1 j. am.m
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