ML20134N819
| ML20134N819 | |
| Person / Time | |
|---|---|
| Site: | Surry, North Anna, 05000000 |
| Issue date: | 08/31/1984 |
| From: | ABB IMPELL CORP. (FORMERLY IMPELL CORP.) |
| To: | |
| Shared Package | |
| ML20134N792 | List: |
| References | |
| NUDOCS 8509050370 | |
| Download: ML20134N819 (43) | |
Text
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- - -e ADMINISTRATIVE CONTROLS ASSESSMENT
- CONCERNING COATING CONTROLS
. . . . AT NORTH ANNA AND SURRY POWER STATIONS mm . ...s. .. . . .. - 1.. . .. . . . . .
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- ' EXHlBlT 26 Page - /--- Ot 25~~. Pages O
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I ADMINISTRATIVE CONTROLS ASSESSMENT (X)NCERNING COATING CONTROLS AT
., NORTH ANNA AND SURRY POWER STATIONS Volume I
- Report I
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' Presented To:
Virginia Electric and Power Company
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Prepared by:
- Impe11 Corporation ,
333 Research Court Technology Park / Atlanta Narcross, Georgia 30092 ,*
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. August,1984 ,
EXHl817 26 ~
Page 3 ,.,ot 28 Pages
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TABLE OF CONTENTS y
i g J 1.0 Introduction 1 -1 2.0 Executive Sumary 2-1
. 3.0 Assessment Technique 3-1 4.0 Scenario Leading to the North 4-1.
i Anna Difficulties
- 5. 0 Observations 5-1 6.0 Recomendations 6-1 Appendices (Separate Volume):
A Documentation of North Anna Ductwork Painting
, B Existing North Anna Administrative Controls C Revised North Anna. Paint Controls D Surry Protective' Coating Program Review E Corrective Measures Taken By YEPCO 9 i 9
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1 EXHIBI- 16 i p g, 0 ot1 Pages l
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1.0 INTRODUCTION
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1.0 INTRODUCTION
i 1.1 Background In July 1984, Virginia Electric and Power Company was informed of a potential safety concern regarding paint that had been applied to the North Anna Unit 1 ring ventilation duct inside containment. Subsequent analysis by VEPCO in response to this ccncern indicated that the unqualified paint used had been applied to the galvanized ductwork in Unit 1 and that another unqualified coating had been applied improperly to the Unit 2 ductwork. -
1.2 VEPCO Response Once knowledgeable of the unqualified coating application at North Anna 1, a three tiered assessment was initiated to detennine:
- 1) The extent of coating errors in existence at Surry and North Anna.
- 2) The insnediate actions to resolve safety concerns.
- 3) The long-term actions necessary to preclude recurrence.
The assessment of issue (1) included both sites and was completed by VEPC0 Jtaffs on August 12 at Surry and shall be completed at North Anna by about August 31. To date no other definite examples of unqualified coating applications at Surry or North Anna have been identified.
' Immediate action was developed to enclose the ventilation ducting at North Anna with 1/8 inch wire mesh. This activity was being pursued by ESC at North Anna and was scheduled for completion by August 25, 1984 for Unit 1, with Unit 2 completion during '
the present outage.
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Station management, QA management, and North Anna EAC had conducted evaluations of the events which had resulted in the application of unqualified paint at ,
North Anna. Both Surry and North Anna had identified !
action plans (see Appendices D and E) to address l issue (3).
VEPC0 management determined that an independent evaluation by an outside consultant was necessary to l assure an objective assessment of the programs which l may have been responsible for this occurrence. Thi s report documents that independent evaluation.
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2.0 EXECUTIVE
SUMMARY
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..,, EXHIBl 26
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l s 2.0 EXECUTIVE
SUMMARY
2.1 North Anna The sequence of events which resulted in the application of unqualified coatings to the North Anna ventilati6n ductwork (see Section 3.0 and Appendix A) in 1983 indicate extensive personnel
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abuse of achinistrative controls.
l J The controls and procedures in existence at the time
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the coatings were applied appear to be adequate both technically and administrative 1y to produce proper*
' applications. Inadequate supervision and QC verification of what appeared to be a mundane task are the root factors in this occurrence. Corrective a measures to preclude recurrence must, therefore, include a combination of increased procedural
'" stringencies and increased personnel attention and knowledge.
Measures to enhance personnel use of procedures have been initiated since the January and June,1983
" timeframe when the North Anna 1 and 2 containment ducts were painted (respectively). However, the more
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complicated control systems and heavy use of
_t contractors by EAC at North Anna dilute the onsite enhancement effort for this group.
The reliance upon QC/QA to conduct management
- supervision of work being perfomed reduces their effectiveness as an objective verification agent. It
' is questionable whether QC was even knowledgeable of
-- the North Anna painting effort, when it occurred.
Conversely, line-management supervision may have been 1
lacking because of the assumption of QC coverage.
.j 2.2 Surry There is no indication that unqualified paint has
- been applied to any surfaces inside either Surry unit ,
containment. Stringent controls maintained by the
'* onsite contractor have alleviated YEPC0 staf f from the necessity for any station control program until recent cleanup efforts prompted Station Maintenance
.. Services to paint portions of the Auxiliary Building.
- Station Controls have been developed since June, 1984, and appropriate qualification requirements and procedures have been initiated, but are not yet complete.
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.. l 2-1 EXHitilT N pge 7 of M Pages
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,l 2.0 EXECUTIVE SIM4ARY 1
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I 2.3 Overview Although coating application *nrograms are different between surry ano-N5rth Anna, their respective-control systems appear to be adequate on paper.
l Implementation of the revised programs needs to include appropriate degrees of training to workers, I '
supervisors, and QA/QC personnel to assure correct utilization. Based on past experience specific management attention may be necessary to assure il adequate implementation.
Associated programs including Consumables Controls, Akinistrative Procedure Implementation, and 1 Evaluation of Safety-Related Activities, also require further review by VEPC0 to preclude similar errors in other areas of maintenance and modification work.
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- J 2-2 EXHlBf ,26 p
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I P.00T CAUSES I. Directly Involved in North Anna Coating App 1tcation Errors: 1983 Personnel failure to use existing procedures and painting specifications; ,y gl Lack non of an effective safety-related evaluation component; of safety-related activity on a Fk Lack of supervisory direction and control; Lack of Quality Control verification of control; '
Incorrect / inadequate documentation of work; -
h Insufficient definition of work requested.
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II. Program Difficulties That May Be Associated at North Anna l Lack of controls for work conducted using a Blanket Work Order; Consumable qualification data difficult to find by users; Contractor supervision in EAC not knowledgeable of control programs at the nuclear site; Responsibilities in review and approval processes not clear and misinterpreted; Administratise burden on Shift Supervisors dilutes their technical evaluation capabilities.
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FIGURE 2-1 (
EXHIBIT,16. ,
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.2 3.0 ASSESSMENT m .. .
TECHNIQUE .
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3.0 ASSESSMENT TECHNIQUE ol i
Mr. E. H. Webster of Impell Corporation conducted the
, , assessment of the VEPCO control programs involved in coating applications at the North Anna and Surry Power Stations. The scope of the assessment is i
defined in Figure 3-1 and was conducted August 13-24, 1984.
l
! During the period August 14-15, the consultant I interviewed North Anna management personnel at the l Plant site. Copies of the documentation which describe the ductwrk painting operations in 1983
, were obtained (see Appendix A). From this and g discussions with Station, QA, and ESC management, the scenario of events in 1983 was developed and the affected programs and procedures identified and obtained (see Appendix B).
The consultant analyzed this data to detemine t practical application, adequacy of controls, and, finally, root causes associated with the improper
, coating application. Since North Anna Station management had already drafted revised coating controls (see Appendix C), these were also obtained and assessed.
] On August 16, the consultant visited Surry Power
, Station, where copies of their applicable control i programs were obtained (see Appendix D). The ir in-house evaluation was reviewed and appeared to be a
,1 q' thorough analysis of the existing program.
Differences between the North Anna and Surry control systems were discussed with both Station management organizations and detemined to be minor.
l During the week of August 20, the consultant
- l completed his analysis of the programs associated I with coating controls and developed the reconnendations in Section 6.0 of this report. These recomendations were discussed with Station j management representatives on August 22 and 23 and finalized in report form on August 24, 1984.
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' ' 3 -1 EXHIBIT. 26 Page ##
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l IN-CONTAINMENT PAINTING CONTP.0LS ASSESSMENT IMPELL, INC.
Scope: 1. Activities to be conducted in the assessment of in-containment painting administrative controls include:
l Evaluation of station (North Anna & Surry) reviews and !
corrective actions taken or planned.
Identification of additional reviews and corrective actions that may be needed.
Documentation of the reviews, findings, corrective actions, and assessment in package form, ensuring both Surry 8 North Anna control programs are addressed.
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- 2. Activities to be conducted based on the result of Item 1 above include:
Identification of other potential problem areas within maintenance, operations, projects, etc. that should be I reviewed.
I APPROVED:
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FIGURE 3-1
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l Action:
Task Date
- k. Item Resp. Completed
- 1. Collect copies of documents and EW 8/15 instructions / controls affected l 2. Evaluate failure mechanisms EW 8/15 j which allowed incorrect paint use
- 3. Document findings and portry EW 8/16 1 root causes .
- 4. Assess root causes as to impact on EW 8/16 .
I other " skill of the craf t" areas
- 5. Develop corrective measures to be MLB & HLM input / 8/22 l implemented to preclude recurrence t.HW
- 6. Document the project work, results EW 8/16 and actions to be taken 1
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J FIGURE 3-1 Page 2 of 2 l EXHIBIT 26 %
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l 4.0 SCENARIO LEADING TO THE NORTH ANNA DIFFICULTIES In June,1982, Maintenance Requests (MRs) were originated to paint the ductwork in the basement of Unit 1 and, separately, Unit 2 containments, to arrest rusting and stains on the ductwork which had resulted from small boric acid leaks in the primary systems. Each of these requests were approved for conduct by Site Construction utilizing a Blanket Work Order in place between Station Maintenance and PIP-N.
4.1 Unit 1 In December,1982, the station turned over the Unit 1 painting authorization to PIP-N. On December 23, the effort was initiated and the Construction Supervisor identified the paint systems and surface preparation specifications to be utilized for this work utilizing QCI 11.1 foms. There is no evidence that QC was infomed of the work nor any documentation to verify the preparation or paint system actually used. The primer selected, Mobil Chromax Red 13-R-50 was not qualified per Painting Specification NAS-1016, and purchase records for the site indicate this paint was never purchased. Further, the SP-10 surface finish called for was not physically obtainable with a grinder (as called for).
The work was documented through February 1,1983 and closed as completed on February 14, 1983 by PIP-N.
1 4.2 Unit 2 In March,1983, the station turned over the Unit 2 painting authorization to PIP-N. The work was accepted by PIP-N in April,1983 and work comenced on April 19, 1983. The paint system selected for this effort was Keeler Long 6548 white primer and white topcoat. The surface preparation was specified as SP-10 using a vacuum blast. ,
Although Keeler Long is qualified for containment c use, the acceptability for application on a galvanized finish was based on a phone call to the
! vendor and was never substantiated. The surface 1 j preparation is not credible in that VEPC0 does not -
own a vacuum blast system, would not sandblast in containment and could not attain an SP-10 finish on ,l f the thin duct sheet metal.
Documentation indicates that the job progressed N through May 1,1983 and was closed on the MR on y[ July 21,1983.
EXHIBIT 16
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l 5.0 OBSERVATIONS
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The consultant's review of existing control programs at North Anna and Surry Power Stations resulted in observations which depict specific facts or errors 1 portrayed in the documentation and from interviews.
's The observations were condensed and grouped according J '
to direct or indirect involvement in the 1983 ductwork painting errors at North Anna. A third group of observations were developed regarding Surry *
] controls to compare and verify adequate program control s.
These findings form the basis of the Root Cause
] detennination, the results of which are presented in Figure 2-1.
] 5.1 North Anna Ductwork Painting: Direct Involvement abservations 1) The utilization of a Maintenance Request (MR) in
} each case for this work was an error since this work constituted a modification. As a result:
- No evaluation was perfortned in accordance J with 10CFR50.59.
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- No in-depth engineering evaluation of
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qualified surface preparation and coating system was conducted.
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- 2) The MRs both denoted the work as not
.- safety-related since the components involved (ventilation ducting) are classified as nonsafety-related. As a result:
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- QC/QA was not notified of the work prior to ,
!- ordering accomplishment. QC signatures for document completion were gained apparently after the work was complete.
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- No documentation directing the use of QCI i . 11.1 nor NAS 1016 was made.
- 3) Paint and surface preparation specifications
- , were not fully in accordance with NAS 1016.
~ 5-1 EXHIBIT. t 6 %
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l 5.0 OBSERVATIONS l .
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- In the Unit 1 case, the Paiftting Specification (NAS 1016) was clearly not utilized.
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- In the Unit 2 case, it appears the Spec.
was consulted, but that the application I .
qualification was not fully substantiated.
- 4) Surface preparation specifications could not, have been met based on engineering evaluation of I tools available, duct wall thickness and time required.
I 5) The paint primer specified for Unit 1 was not utilized.
- Purchase records show that this paint (Chromax) was never purcht. sed or batched for tif t 1 and 2.
- Records indicate a Cheesman/Debevoise Deveka No. 505 was on hand and batched in the December,1982 timeframe. This paint I is also an alkalyd base but equivalency to Mobil Otromax 13R-50 is not established.
- 6) The construction supervisor responsible for identifying preparation specifications and coating specifications is no longer employed by ~
YEPCD, 1
] 7) Documentation for the work does not specify that 3 the surface was galvanized, nor does it specify the surface area intended to be covered. c
- 8) Records indicate that only 17 gallons of Deveka No. 505 were batched in the affected timeframe which is not sufficient to have primed the j entire surface. 111 gallons of topcoat were batched.
4 ia 5-2 EXHIBIT,.
, ,, g Ib ,,,es i
g g,,,
L
5.0 OBSERVATIONS O
5.2 North Anna Ductwork Painting: Indirect Involvement Observations: 1) The Consumables Control Program implemented in 1983 has created a data base which is difficult to access by worters.
- An extremely large number of consumables have been qualified by EWR subsequent to the program implementation. 1.istings of
' these consumables and their appropriate qualification have never been incorporated into the prsgram aministration.
- Consumable Controls to assure shelf life, service life, and in the case of coatings, operating (pot) life, were frequently mentioned as missing from the existing program.
- 2) Plant modifications as defined in Administrative Procedure 3.7 may be instituted by Design Change l Package (DCP) of Engineering Wort Request (EWR).
- Both DCP and ENR programs appear to afford sufficient controls to assure proper ;
reviews of the modification. l
- Maintenance Requests are not an authorized i mechanism to affect modifications, but there appear to be no controls to screen out requests (MR or WO) which result in modifications.
- 3) Review signatures are required for all ,
documentation involved in design, modification, and maintenance controls.
- Most personnel contacted expressed the belief that a QC signature indicated l in-depth technical, akinistrative and l safety verification of the document and its associated work / operation.
n 5-3 EXHIBIT. I k i Page .fl of I I Pages
5.0 OBSERVATIONS l
I l
l l
- QA/QC expressed a contrasting view that many of their document signoffs only verify that the documentation has been completed l properly.
- Shift Supervisor approval is required on 1 .
all documents affecting the plant. Due to
. the volume of documents involved, the value of this approval is anticipated to be
- 1 limited to safety evaluation at best, although many personnel believed that this included technical approval also.
- 4) Programatic controls utilizing procedures to implement each program have been instituted to meet regulatory requirements and properly
] operate, maintain and modify the plant and associated systems.
Apparently because of the sequence of
)
- development of construction-related procedures, some confusion was expressed
,] regarding which procedures Construction is required to use. (PMP, SOP, ADM)
-
- Since Construction supervision below Superintendent level is primarily filled by contractors and little or no training is
_ given these people outside of (AIT, weakness in procedural compliance is to be expected
<- unless VEPCO direct supervision is maintained.
- Complacency and/or lack of knowledge of controls established by Administrative
i- Procedures was expressed as a concern by several managers.
. 5) 10CFR50.50 reviews are instituted in the controls for DCPs, EWRs, end temporary changes.
I 5-4 EXHIBIT 26-Page 4 of I Pages l]
5.0 OBSERVATIONS O
- Controls in the above named programs appear to be adequate.
- Maintenance Requests, when annotated nonsafety-related, non-Tech. Spec., do not get screened for 10CFR50.59 review.
I . Maintenance which impacts safety-related equipment could, therefore, proceed without review. .
5.3 Surry Power Station 1) Painting conducted in containment at Surry prior to 1984 appears to have been conducted by the onsite contractor, Daniel, using Procedure l WP 114.
>] 2) The Maintenance Services Group at Surry has J conducted aesthetic painting outside ccntainment and is now controlled by Administrative Procedure ADM 102.
- ' 3) Station evaluation of existing controls has already identified weaknesses and enumerated corrective actions to revise ADM 102, QCI 10.10 and develop MSP procedures to increase the amount of painting Maintenance Services can perfonn.
- 4) A review of the sampling by Station management
- , of previous design changes, including
- j installation of ductwork in containment, reveals no unqualified coating utilization. This review also included a review of the paint applied by Maintenance Services on the liner basement,
,. inside containment.
- 5) Paint is stored in two locations. The warehouse
,, supporting Construction Stores " CAT I" paint, another station warehopse stores paint which is i
not vendor certified.
d 1
l 5-5 EXHIBIT. !6 %
Page If._of M pages
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- ' 6.0 RECOP9tENDATIONS. ~
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- .. s EXHIBIT. t 6 Page b1 n ges a
6.0 RECOPMENDATIONS
)
l Based on the observations and root causes identified by the consultant, the following general recomendations were developed to provide Virginia Electric and Power Company with the long-tem corrective measures to preclude future coating application errors. Items identified by an asterisk 1 ,
(*) have alreatty been addressed by station originated corrective actions comf tments.
6.1 Both Stations 1)* Implement controls for the selection of surface preparation and coating applications which
, reference existing Painting Specifications.
there coating of in-containment surfaces or safety-related equipment is involved, secondary evaluation and verification controls involving Quality Control personnel should be specified and
. documented.
. 2)* Conduct training for maintenance and applicable construction personnel including supervisors on the coating difficulties that occurred at North Anna, the hazards of coating misapplication, and the controls established to assure correct
, applications.
l- 3) Establish system interaction and design basis knowledge at the ESC supervisory and SEO personnel level to develop increased engineering
. sensitivity.
- 4) Provide continuing training on station adninistrative controls with emphasis on specific review and approval responsibilities involved in
, existing programs.
- 5) Clarify line-management and QA/QC roles and S responsibilities to assure objective verification l processes exist. ;
- 6) The mechanisms authorized to request coating i c applications should be controlled as potential i modifications and should specify surfaces to be j coated:
(
q d
, 6-1 EXHIBIT. 26 ~.
Page D oL I I . Pages
6.0 RECOMMENDATIONS l
1 Area to be coated, identifying boundaries Existing surface material to be coated Reason for coating (e.g.: rust, abrasion, appearance)
- 7) Upgrade existing consumables controls:
to provide a comprehensive listing of qualified materials and qualified ,
applications; to control consumables once issued to the field to assure traceability.
- 8) Review and revise existing EAC instri.ctions to provide a single integrated set of controls for each site-specific organization.
- 9) Review the Shift Supervisor akinistrative workload and adjust as necessary to assure responsibilities can be met.
6.2 North Anna Power station 1)* Detemine and control the involvement of Station Maintenance Department in coating application.
- 2) Establish and enforce controls of the Blanket Work Order between Maintenance and Construction to assure coating controls and documentation. l
- 3) 1 Establish and maintain a minimum knowledge level l by Construction Supervisors of nuclear plant control and ahinistrative systems.
6.3 Surry Power Station 1)* Complete the. administrative controls and '
procedures to be used by Maintenance Services to apply coatings, and implement a qualification program for those personnel involved in surface i
preparation and coating applications. '
2)* Implement controls to specify the types of coating application for which Maintenance Services and the onsite contractor are qualified and authorized to conduct.
6-2 EXHIBITM Page U of Pages
t
! 6.0 RECOMMENDATIONS 1
.1 i
3)* Verify that paint specifications which originate from the original Surry Paint Specification for in-containment applications include DBE evaluation.
A t
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4 6-3 EXHIBIT 24%
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POW 3b-18
%..oroisono MEMORANDUM To A. D. Fraley, Jr. North Anna FROM C. C. Ludden October 15,1984 HISTORY OF RING DUCT C0ATINGS UNIT I AND 11 NORTH ANNA POWER STATION As requested, we have assembled doumentation to support the coating sequences for the ring ducts on North Anna Units I and II. The Protective Coating Surface Preparation Records (PCSPR) for the two units are shown in Attachments 1 and 2. Although these records are complete, questions have been raised regarding the actual primer used in Unit 1 and the type of surface preparation actually performed.
SURFACE PREPARATION Each PCSPR indicates that an SP-10 surface was to be obtained in pre-paration for primer coating. Unit I records indicate that a grinder was
' used; Unit 2 records indicate that the surface was vacuum blasted.
Although SP-10 is a specification for sandblasting; it is common industry practice to quote an SP standard when using other types of surface prepara-tion. The SP-10 notation would indicate prepararion of the surface by the specified means to a cleanliness equivalent to that obtained by an SP-10 bladt. Thus, there is no conflict on the Unit 1 PCSPR's regarding that point.
The vacuum blasting indicated on the Unit 2 records could not have been accomplished as North Anna does not have vacuum. blasting equipment and does not allow blasting of any type in containment."
Discussions with Vepco construction and painting shop personnel indicate that the following surface preparation technique was used for both Units 1 and 2. Hand held grinders were used to prepare areas of boric acid corrosion and the remaining surface was hand sanded to a cleanliness equivalent to SP-10, as described above.
UNIT 1 PRIMER IDENTIFICATION Although the Unit 1 PCSPR's indicate that Mobil Chromox Primer Red 13-R-50 was used, there is substantial evidence to show that Dereka Prin.er Red No. 505 was actually used. First.
indicated that Mobil Chromox Primer has,a notreview been of station purchasing purchased records by the station (Attachment 3). Second, discussions with Vepco construction and painting shop personnel indicate that Dereka No. 505 was used, Finally, a review of painting shop batch records (Attachment 4) indicates that Dereka No. 505 was batched and used during the period the ring duct was costcJ.
Both the Mobil Chromox and the Dereka No. 505 coatings are alkyd based primers. Infrared spectroscopy performed on coating scmples taken from the Unit I duct show that the primer was alkyd based, consistent with the Mobil or Dereka primer (Attachement 5).
EXHIBIT 27-Page / of 1 Pages
4 Pega 7 Octcb::r L 15,1984; HISTORY OF RING DUCT COATINGS I
i d4 George C. Ludden GCL/smb Attachments cc: J.R. Locklar FB-6 H.J. Fortune, Jr. EB-9 R.B. Green EB-7 R.M. Berryman EB-3
.~
f 9
37 -
pfge 1- N8"
MTTE NHC A/T 3 MEMORANDUM To Mr. A. D. Fraley, Jr. North Anna Purchasing FROM K. V. Cummings October 15, 1984 PURCHASE OF MOBIL 13-R-50 Purchasing was asked to determine if in fact we had purchased any Mobil 13-R-50 in the year 1982. We conducted a review of all orders placed with Mobil or Mobil distributors for the time frame in question. No such purchase was found on either the Construction or Operations side.
To verify our findings, Mobil Chemical Company was also contacted and asked to research their records since all purchasing at that time was not done on site. Their records did not indicate that Mobil 13-R-50 was provided to Vepco's North Anna site.
Investigations did reveal that Mobil has supplied on two occasions Mobil 13-R-53. However both shipments totaled only fifteen (15) gallons.
. The purchase orders involved were NA3-4667 dated September 28,1982, for ten (10) gallons and purchase order number NA3-2516 dated February 22, 1982, for five (5) gallons.
~
'. V- s K. V. Cummings ,
Supervisor Purchasing
,. t
(
C EXHIBIT ~*
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a ercc d , contents thoroughly re and t wtpie using. Surface t .out be thor- ""k4 Nt. t# s
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"."" 4'":i l P/ e 6 id r g Kn t and sa y we I should oe sealed with r o.a4 '2 ' ' '?
queJac. ,I c# ,k ces or hen e te hr t i materia sh id ts I a te ature of 70* f befo5e ing apphe i All defects in the ffAace shg.utd be -
t:e r per y prir e or spot pe d L AUTION! COMBUSTIBLEI Keep a y from beat and open flom iS prolonged contact with sk a
- Lefore this product is apphed laid breathing of vapor or spro Ise only with odequate ve Do not take in (noll e g Kt Close container of ter each usej OUT Of REACH OF CHILORtN}
(
New concerte plaster, ett - gouk, be sea:ed with Latex Pri.
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THE DEBEV0lSE NY BROD YN, N.Y.11232
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