ML20236P352
| ML20236P352 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 08/04/1987 |
| From: | Charemagne Grimes NRC OFFICE OF SPECIAL PROJECTS |
| To: | |
| Shared Package | |
| ML20236P230 | List: |
| References | |
| 50-445-87-07, 50-445-87-7, 50-446-87-06, 50-446-87-6, EA-87-122, NUDOCS 8708120305 | |
| Download: ML20236P352 (36) | |
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ENCLOSURE 1 l ' NOTICE OF VIOLATION Texas Utilities Electric CN pany Docket Nos. 50-445; 50-446 400 North Olive Street, Lock Box 81 Permit Nos. CPPR-126; CPPR-127 Dallis, Texas 75201 EA 87-122 During an NRC inspection conducted during the period from March 1 through April 30, 1987, the NRC staff reviewed the circumstances associated with a construction deficiency related to the floor mounting conG*tions for the 6.9 kv switchgear. The NRC was notified of this reportable oeficiency on February 13, 1987. The failure to report this deficiency in September 1986 when the vendor identified the significance of the deficiency constitutes d violation of NRC requirements. In accordance with the " General Statement of Policy and Procedure for NRC Enforcement Actions," 10 CFR Part 2, Appendix C (1987), the violation is set forth below:
10 CFR Part 50.55(e) requires, in part, that the Commission be notified within 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> of each deficiency in design and construction which.
- were it to remain uncorrected, could have affected adversely the safety of operations at any time throughout the expected life of the plant, and which represents a significant deficiency in construction which will require extensive evaluation, extensive redesign, or extensive repair to meet the criteria and bases stated in the safety analysis report or to establish the adequacy of the structure or component to perform its intended safety function.
Contrary to the above. TU Electric Company did not report a construction deficiency within twenty-four hours of notification of its significance.
By letter dated September 5,1986, Brown-Boveri notified TU Electric that deficiencies in the installation of Class 1E C.9 kv switchgear could cause failure of the equipment in a seismic event. On February 13, 1987, approxi-mately five months later, TV Electric notified the NRC of the deficiency.
The deficiency required extensive repair to establish the adequacy of the components.
This is a Severity Level IV violation (Supplement II).
Pursuant to the provisions of 10 CFR 2.2,01, TU Electric Company is hereby '
required to submit a written statement or explanation to the U.S. Nuclear Regulatory Commission within 30 days of the date of this Notice. This reply should be clearly marked as a " Reply to a Notice of Violation" and should include for each alleged violation: (1) admission or denial of the alleged violation, (2) the reasons for the violation if admitted, (3) the corrective steps that will be taken to avoid further violations, and (4) the date when full compliance will be achieved. If an adequate reply is not received within the time specified in this Notice, an order may be issued to show cause why 1
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the license should not be modified, suspended, or revoked or why such other action as may be proper should not be taken. Consideration may be given to extending the response tirne for good cause shown. Under the authority of.
Section 182 of the Act, 42 U.S.C. 2232, this reponse shall be submitted under oath or affirmation.
The response to this Notice should be addressed to: U.S. Nuclear Regulatory Commission, ATTN: Document Control Desk, Washington, DC 20555, with a copy to the Director, Office of Special Projects .and a copy to the NRC Resident Office et the facility which is the subject of this Notice.
FOR THE NUCLEAR REGULATORY COMMISSION Otu2>denw 'I. G5/u.uuA Christopher I' Grimes, Directok Comanche Peak Project Division Office of Special Projects j
Dated pt Bethesda, Maryland, 1 this (Hh day of August,1987 I
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ENCLOSURE 2 i
TU ELECTRIC PRESENTATION ENFORCEMENT CONFERENCE JUNE 6, 1987 0
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CHRONOLOGY: SDAR-CP-87-03 (SN-220) 6.9 KV SWITCHGEAR INSTALLATION HOVEMBER, 1985 NCR E85-201646S ISSUED DOCUMENTING MISALIGNMENT CONCERNS OF BREAKERS IN ,
THE UNIT 2 INSTALLATION. )
NOVEMBER 1985 TO TU ELECTRIC AND THE VENDOR (BBC)
AUGUST, 1986 PERFORMED A SITE INVESTIGATION OF BREAKER CONDITIONS.
SEPTEMBER 5, 1986 BBC ENGINEERING INSPECTION REPORT ISSUED. i SEPTEMBER, 1986 TO SITE ENGINEERING TRANSITION OCCURS NOVEMBER 1986 (INVOLVING G&H TO SWEC)
JANUARY 14, 1987' BBC LETTER RECOMMENDED COMPLETE REWORK OF THE UNIT 1 SWITCHGEAR FOUNDATION.
FEBRUARY, 1987 TO UNIT 1 SWITCHGEAR. REPAIRED MAY 1987 - -
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FEBRUARY 12, 1987 REPORTARILITY EVALUATION FORM (SN-220)
ISSUED DOCUMENTING INSTALLATION j DEFICIENCIES.
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FEBRUARY 13, 1987 LICENSING VERBALLY NOTIFIED THE NRC 0F A REPORTABLE DEFICIENCY PURSUANT TO 100,Rs0.ss e L0 m o S Cr ez.os.
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COMPARATIVE TRENDS REPORTED AS FINAL "P0TENTIALLY" ASSESSMENTS REPORTABLE REPORTABLE FACILITY PERIOD 10CFR50.55(E) 10CFR50.55(s)
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o 24 NOTIFICATIONS STILL PENDING FINAL DEPORTABILITY EVALUATION.
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NONCONFORMANCE CONTROL PROGRAM I. Describe the nonconformance co((rol program as it relates to discovery and initiation of corrective actions to resolve nonconforming conditions.
II. Address each of the NRC findings. '
III. Describe how the nonconformance control program meets 10CFR50 Appendix B Criterion XV.
IV. Conclusion 1
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DEFINITIONS Rework - The process by which a nonconforming item is made to conform to -prior specified requirements by corrective means.
Es.nair. - The process of restoring a nonconforming characteristic to a condition such that the capability of an item to function reliably and safely is unimpaired, even though that item still does not conform to the original requirements.
Scran - The determination that an item is not acceptable for use in a safety related application and must be segregated or disposed of to preclude such use.
Use As-Is - A disposition which may be assigned for a nonconformance when it can be established that the discrepancy shall result in no condition adverse to safety and that the item under consideration will continue to meet all engineering functional requirements.
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I Heirarchy of Documents for
- Operations Nonconformance Control Program OAC/OAP Operations Administrative Control & Quality '
Assurance Plan NEO-3.05 Reporting and Control of Nonconformances STA-405 Control of Nonconforming Materials i
i i Nonconforming conditions Nonconforming conditions prior to leaving warehouse after leaving warehouse i I j WHS-001 STA-606 1 Receipt and Inspection of Work Requests ;
Materials, Parts and and Work Orders Components ,
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NRC FINDINGS NRC FINDING NEO 3.05 contains wording that appears in variance with Criterion XV by adding the phrase "...and cannot be corrected within the scope of such requirements or otherwise [ sic] requires an Engineering disposition" to the applicability statement. This appetrs to mean if it can be fired by some-means, it is not nonconforming and does not need to be reported as nonconforming.
RESPONSE
NEO 3.05, " Reporting and Control of Nonconformances", paragraph 2.1 states "This procedure is applicable to quality related items or conditions which deviate from drawings, specifications, or other engineering requirements and cannot be corrected within the scope of such requirements or otherwise requires an lingineering disposition."
The wording in paragraph 2.1 means that any nonconforming condition which is dispositioned " repair", or "use-as-is", which by definition requires Engineering approval, must be accomplished in accordance with NEO 3.05 by using a Nonconformance Report. Items which can be corrected within the scope of existing engineering requirements and require no Engineering input (i.e., " rework" or " scrap") may.be corrected in accordance with that organization implementing procedures. In the case of Operations this means the Work Request / Work Order Program.
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p NRC FINDING A note contained in Section 6.0 of NEO 3.05 states, "Nonconformance Reports shall be prepared on items when a ' repair' or 'use-as-is' disposition is required." The meaning here appears to be that the type of disposition is the judging factor for writing Nonconformance Reports (NCR's), not that a nonconforming condition exists.
RESPONSE
The fact that an item does not meet specified requirements is the criterion used to determine an item is nonconforming. An NCR is required for nonconforming conditions requiring a " repair" or "use-as-is" disposition.
If the item can be reworked, a Work Request / Work Order is written to l
identify and correct the nonconforming condition. !
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x... i NRC FINDING Section 6.4 of NEO 3.05 starts with a ' sentence that reads, "Upon discovery of a nonconforming condition, it should be determined if an NCR is required." This again relates to the above note for determining NCR requirements by the type of disposition. >
RESPONSE
NEO 3.05, " Reporting and Control of Nonconformances", paragraph 6.4 states, in part, "Upon discovery of a' nonconforming condition' it should be determined if an NCR is required. Work documents or NCR's shall be prepared to correct the nonconformance by rework- or replacement. If the item cannot be reworked or replaced a Nonconformance Report shall always be originated." !
-This _ paragraph clearly establishes and acknowledges that a ;
. nonconforming condition exists. The question remaining is, can it be reworked, repaired, or used as is. 'If it can be reworked, then a work document such as the Work Request / Work Order can be used. If not, then an NCR must be written to get Engineering approval of the " repair" or use-as-is" and dispositioned.-
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. . - i NRC FINDING Section 6.5 of NEO 3.05 tasks QA/QC to perform an evaluation of NCR's.
The evaluation is to " determine if the NCR is valid, complete, and sufficiently detailed so the problem can be clearly understood and located." The steps following this section provide no guidance for determining validity. Discussion with a representative of the applicant's QA/QC department indicated that if an NCR could be written up on a Work Request, the QA/QC evaluator would invalidate the NCR. However, once the NCR has been invalidated and returned to the initiator, there is no explicit procedural instruction requiring the initiator to write up a Work Request.
RESPONSE
The validity review performed by Quality Assurance is for two reasons. I First, to assure that a nonconforming conditions exists, and second to assure that items which can be reworked are reported using the Work Request / Work Order.
Clear guidance does exist in STA-40.5 for direction as to what must be Paragraph 4.2.2.1 of STA-405 states:
done once an (N]' is discovered. ,
nonconforme og cond etion "The reporting of nonconformances that are on installed plant equipment shall normally begin with th,e initiation of a work request and work order, and notification of the Shift Supervisor."
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. .- i NRC FINDING Implementing Procedure STA-405, "( ontrol of Nonconforming Materials".
states that those identified nonconfor.uing conditions that can be dispositioned by " rework" or " scrap" (i.e. replace) need not be reported on nonconformance reports. Again, as in NEO 3.05, it appears that the l criteria for writing NCR's is the method of disposition, not the fact that an item is nonconforming. Additionally, the procedure is in variance with Section 3.9, paragraph 4 of the OAC/QAP above which requires an NCR to be prepared which identifies and describes the nonconformance.
RESPONSE
Section 3.9 paragraph 4 of the Operations Administrative Control and Quality Assurance Plant (OAC/QAP) states, in part:
" Materials, parts and components which are determined to be nonconforming, shall be identified and reported.
Nonconformance reports shall be prepared which identify and describe the nonconformance, the disposition of the nonconformance and reinspection or testing performed to determine the acceptability of the item after the disposition has been completed.
The term "nonconformance reports" as used in this paragraph was intended to have a broader definition than Nonconformance Reports (NCR's). The practice of using Work Request / Work Order and previously Maintenance Action Requests as nonconformance reports has been in place since 1980. For nonconforming conditions dispositioned " rework" or
" scrap", the WR/WO meet all the requirements for identifying and describing the nonconforming conditions, the dispositions, and the reinspection and/or testing.
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, . . . i NRC FINDING l
The . applicability statement of STA-405. requires nonconforming conditions ' discovered during receiving inspections to be identified- as nonconformances. In addition, the definition of nonconformance defines deficient documentation as a nonconforming condition.
Contrary to this, STA-405 also allows items which are nonconforming during receipt inspection to be placed in a "QC Hold" area' without
, preparing an NCR.
Resnonse i
. The practice described by this finding is accurate. However, procedure WHS-001, " Receiving and Inspection of Materials , Parts and Components", requires that the Receiving Inspection Report be checked UNSAT and the. discrepancy be described in the " Remarks" section of the RIR. A Receiving Hold tag is then attached to the item and the item placed in a designated hold area. At this point an attempt is m'ade to retrieve the missing documentation.- If the missing documentation is retrieved' then a reinspection is performed -
and, if acceptable, the RIR is checked SAT and the item accepted for placement into 'the warehouse. However, if the documentation- is not received then an NCR is written. !
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COMPARISON OF NONCONFORMANCE CONTROL PROGRAM TO CRITERION XV 10CFR 50 Appendix B, Criterion XV, " Nonconforming Materials, Parts or Components" states:
" Measures shall be established to control materials, parts or components which do not conform to requirements in order to prevent their inadvertent use or installation."
This portion of Criteria XV is addressed in that STA-405 paragraph 4.1.1 requires that "All station personnel are responsible for reporting nonconforming conditions discovered." There are two methods outlined in STA-405:
- 1) the Work Request / Work Order and 2) the Nonconformance Report (NCR).
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.> v 10CFR 50 Appendix B, Criterion 'XV, " Nonconforming Materials, Parts -
. or Components" states:
"These measures shall ' include, as appropriate, procedures for identification, documentation, segregation, disposition and notification to effected organizations."
These requirements of Criterion XV are met in the following manner:
A. Identification - STA-405 requires that all personnel report nonconforming conditions. In addition , various inspection, engineering and maintenance procedures also require reporting of nonconforming conditions in ;
accordance with STA-405.
B. Documentation - After items are released from the warehouse STA-405 requires that a nonconforming condition be identified either by a Work Request / Work -
Order or an NCR. In the case of receiving, the item held pending receipt of documentation without writing an NCR are documented as and UNSAT on the Receiving Inspection Report. The RIR cannot be closed without the RIR item checked SAT or an NCR written.
C. Segregation - Items received into the TU Warehouse are procedurally required to be segregated or otherwise identified as not being receipt inspected. Once . inspection is performed and the item is determined to be nonconforming, it is further identified as nonconforming and placed in a Nonconforming Hold Area.
Items which are found nonconforming after release from j the TU Warehouse generally cannot be segregated.
However, items found nonconforming are identified by a Work Request Tag (when practical) which is placed on the nonconforming item. If an NCR is written, Hold Tags are used (when practical) to identify the nonconforming conditions.
Both the Hold Tag and the Work Request Tag are not attached under the following conditions:
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- a. hanging the tag would be detrimental to the L individual's safety; L
- b. the individual's exposure to radiation will be unnecessarily increased;
- c. the item is on the main control board in the control room; and
- d. the tag would interface with component operation.
D. Disposition - All nonconforming items are dispositioned as rework, repair, scrap or use-as-is. Items which .
require engineering approval (repair and use as is) are documented on the NCR. Rework and scrap (replace) dispositions restore the item to an existing engineered condition.
E. Notification - In the case of installed items found nonconforming while operating the plant, the shift supervisor is notified immediately so the plant can be placed in a safe operating condition should the condition warrant such an action. This requirement applies to the Work Request and the Nonconformance Report. In : cases where and NCR or Work Request is generated on non installed itemt , the person responsible for correcting the condition is notified.
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10CFR 50 Appendix B,. Criterion XV, " Nonconforming Materials, Parts cr. Components" states:
" Nonconforming items shall be reviewed and accepted, rejected, j
repaired or reworked in accordance with ' documented procedures." '
I These requirements of Criterion XV are met in the following manner:
The nonconformance control program requires that - a nonconforming condition must be repaired, reworked, rejected (scrapped) or accepted (use as is). The nonconformance control program clearly defines these dispositions and provides measures to assure that engineering review is performed when necessary. All dispositions must be implemented in accordance with. written procedures and/or instructions.
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CONCLUSION
- TU Electric finds that the nonconformance reporting- program meets the provisions; of 10 CFR 50 Appendix B Criterion XV. -However, the TU Electric review of the program conducted as a result of the NRC finding reveale'd that improvements can be made in the program. A summary of these program enhancements which will be made follows:
. Revise the OAC/QAP to more clearly define the specific use of the Work Request / Work Order as a nonconformance - report. l l
. Revise procedures to to cle.trly define the use of the term. -l
" invalidate."
Revise WHS-001 to more clearly define placing items on hold without writing and NCR.
. Revise procedures to clearly describe the use of the Equipment History Program .in identifying repetitive vendor . deficiencies.
i Revise procedures .to clearly describe Operations role and responsibility in timely review of. Work -Requests / Work Orders - for 10CFR21 and 50.55(eV reportable conditions.
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)R O XXXXXXXXXX PRIORITY XX WORK ORDER # CXXXXXXXXX Scheduled Date XX/XX/XX Rev. # 0 locponrible OrganizO: ion
- XXXX XXXXXXXXXXXXXXXXXXXXXXXXXX
)uality Related . XX Safety Class XX
'AG # XXXXXXXXXXXXXXXXXXXX ITEM /DESC: XXXXXXXXXXXXXXXXXXXXXXXXXX Jnit XXX System XXX Train XX Bldg. / Elev. XXXXXX Room AXXXXXXX PROBLEM OBSERVED / WORK REQUESTED XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
)R I GI N ATOR XXXXXXXXXXXXXXXXXXXX Dat e Peport ed XX/XX/XX londi t ional Release (Y/N) #: -
'och Spoc (Y/N) X Start (Tine _ XX:XX Date XX/XX/XX) Req'd Comp 1 . / /
3****o**************** CONDITIONS REQUIRED TO PERFORM WORK *************+*******
9 nit Mode . XX System XX Equipment XX s lpocial _
i*o************************** SPECIAL INSTRUCTIONS ****************************
)ERMITS: RWP YN # Confined Space Entry Y N #
FIRE Y N Combustible Loading Y N Clocrance YN # -
Cleanness Class __
Housekeeping Zone __
i+0****u******u*************** PREWORK REVIEWS *******************u*+++*****
N FA FAILURE ANALYSIS D at e / /
N WELD WELDING Dat e / /
N ISI INSERVICE INSPECTION Date / /
N RR REPAIR / REPLACEMENT Dat e / /
N RE RESULTS ENGINEERING Date / /
N OC QUALITY CONTROL IR Y N Date / /
N AN!! AUTHORIZED NUCLEAR INSP. Date / /
N PS PLANNING AND SCHEDULING Date / /
N Date / /
Rev. l Date l FA l WELD l ISI l RR l RE l GC l ANII l Org. l AS I I I I I I I I I I l l 1 I l I I I I l __
l l I I I I I I I I loo****************** APPROVAL / AUTHORIZATION TO START WORK ********************
Jork Order Issued To Dat e / /
lXXXXXXXXXXXXXXXXXXXXXXXXX - Date / /
>uthorizing Supervisor (AS) Date / /
- WORK COMPLETE **********************++++*4++*
- XXXXXXXXXXXXXXXXXXXXXXXXX Date / /
)C Lavol II Date / /
>uthorizing Supervisor Date / /
4******++**+*******u*u******+ POST WORK REVIEWS ***************:=t***++6*+***
'oiluro Code XX Activity Code XX
>ccount # XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
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Tag Comments -
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX eo******************************* WORK PLAN **************************4- *t***.4 MANPOWER ESTIMATES MEASURING AND TEST EQUIPMENT (entor actual # men and hrs, worked) M&TE TAG # CAL DUE M&TE TAG # CAL DUE
XXX / XXXX .XXXX.X/ ._ XXX / / / /
'XXX / XXXX XXXX.X/ . XXX / / / /
XXX / _ ., XXXX XXXX.X/ . XXX / / / /
XXX / XXXX XXXX.X/ . XXX / / / /
SPARE PARTS AND SPECIAL TOOLS Quentity (enter actual used and cross out any not used)
Est / Act U/I TSN GAT Description XXXX.X/ ._ XX XXXXXXXXXXXXXXXX QAT XXXXXXXXXXXXXXXXXXXXXXXXx/ .j XXXX.X/ . _ , XX XXXXXXXXXXXXXXXX QAT XXXXXXXXXXXXXXXXXXXXxXXXXX ;
XXXX.X/ . _ , XX XXXXXXXXXXXXXXXX OAT XXXXXXXXXXXXXXXXXXXXXXXXXX ,
XXXX.X/ ._ XX XXXXXXXXXXXXXXXX QAT XXXXXXXXXXXXXXXXXXXXXXXXXX
- +++* PROCEDURES / INSTRUCTIONS * * * * * * * * * * * * * * * * * * * * * * * * * *
- XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX 4
WORK INSTRUCTIONS Steps Resp Org. Performed NA XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX [ ] [_3 XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX C 3 C__]
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX C 3 C __,3 XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX [ ] C ,__ J XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX C 3 [__3 XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX C 3 (__]
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- +***********+++ WORK PERFORMED / PROBABLE CAUSE *******+****************
Duration (Est./Act ) XXXXX.X / ._
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