IR 05000391/2014611: Difference between revisions

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| issue date = 05/15/2014
| issue date = 05/15/2014
| title = IR 05000391-14-611, 04/21-25/2014, Watts Bar, Unit 2, Problem Identification and Resolution Inspection
| title = IR 05000391-14-611, 04/21-25/2014, Watts Bar, Unit 2, Problem Identification and Resolution Inspection
| author name = Haag R C
| author name = Haag R
| author affiliation = NRC/RGN-II/DCP/CPB3
| author affiliation = NRC/RGN-II/DCP/CPB3
| addressee name = Skaggs M D
| addressee name = Skaggs M
| addressee affiliation = Tennessee Valley Authority
| addressee affiliation = Tennessee Valley Authority
| docket = 05000391
| docket = 05000391
Line 18: Line 18:


=Text=
=Text=
{{#Wiki_filter:May 15, 2014  
{{#Wiki_filter:May 15, 2014


Mr. Michael Senior Vice President Nuclear Generation Development and Construction Tennessee Valley Authority 6A Lookout Place
==SUBJECT:==
 
WATTS BAR NUCLEAR PLANT UNIT 2 CONSTRUCTION - NRC PROBLEM IDENTIFICATION AND RESOLUTION INSPECTION REPORT 05000391/2014611
1101 Market Street Chattanooga, TN 37402-2801
 
SUBJECT: WATTS BAR NUCLEAR PLANT UNIT 2 CONSTRUCTION - NRC PROBLEM IDENTIFICATION AND RESOLUTION INSPECTION REPORT  
 
05000391/2014611


==Dear Mr. Skaggs:==
==Dear Mr. Skaggs:==
On April 25, 2014, the U.S. Nuclear Regulatory Commission (NRC) completed an inspection of construction activities at your Watts Bar Unit 2 reactor facility. The enclosed inspection report documents the inspection results, which were discussed on April 25, 2013, with you and other members of your staff.
On April 25, 2014, the U.S. Nuclear Regulatory Commission (NRC) completed an inspection of construction activities at your Watts Bar Unit 2 reactor facility. The enclosed inspection report documents the inspection results, which were discussed on April 25, 2013, with you and other members of your staff.


This problem identification and resolution (PI&R) inspection examined activities conducted under your Unit 2 construction permit as they relate to identification and resolution of problems, compliance with the Commission's rules and regulations, and with the conditions of your construction permit. The inspectors reviewed selected procedures and records, observed activities, and interviewed personnel.
This problem identification and resolution (PI&R) inspection examined activities conducted under your Unit 2 construction permit as they relate to identification and resolution of problems, compliance with the Commissions rules and regulations, and with the conditions of your construction permit. The inspectors reviewed selected procedures and records, observed activities, and interviewed personnel.


No findings were identified during this inspection.
No findings were identified during this inspection.


In accordance with 10 Code of Federal Regulations (CFR) 2.390 of the NRC's "Rules of Practice," a copy of this letter, its enclosure, and your response (if any) will be available electronically for public inspection in the NRC Public Document Room or from the Publicly Available Records (PARS) component of the NRC's document system (ADAMS). ADAMS is accessible from the NRC Web site at http://www.nrc.gov/reading-rm/adams.html (the Public Electronic Reading Room).
In accordance with 10 Code of Federal Regulations (CFR) 2.390 of the NRCs Rules of Practice, a copy of this letter, its enclosure, and your response (if any) will be available electronically for public inspection in the NRC Public Document Room or from the Publicly Available Records (PARS) component of the NRCs document system (ADAMS). ADAMS is accessible from the NRC Web site at http://www.nrc.gov/reading-rm/adams.html (the Public Electronic Reading Room).


UNITED STATES NUCLEAR REGULATORY COMMISSION REGION II 245 PEACHTREE CENTER AVENUE NE, SUITE 1200 ATLANTA, GEORGIA 30303-1257 Should you have questions concerning this letter, please contact us.
UNITED STATES NUCLEAR REGULATORY COMMISSION  
 
==REGION II==
245 PEACHTREE CENTER AVENUE NE, SUITE 1200 ATLANTA, GEORGIA 30303-1257 Should you have questions concerning this letter, please contact us.


Sincerely,
Sincerely,
/RA/ Robert C. Haag, Chief Construction Projects Branch 3 Division of Construction Projects
/RA/  


Docket No. 50-391 Construction Permit No: CPPR-92 Enclosure: Inspection Report 05000391/2014611 w/Attachment
Robert C. Haag, Chief


cc w/encl: (See next page)
Construction Projects Branch 3


_ML14135A428 _
Division of Construction Projects
SUNSI REVIEW COMPLETE FORM 665 ATTACHED cc w/encl:
Mr. Gordon P. Arent Director, Licensing Watts Bar Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City, Tennessee 37381


Mr. O. J. Zeringue, General Manager Engineering and Construction WBN Unit Two Watts Bar Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City, Tennessee 37381
Docket No. 50-391 Construction Permit No: CPPR-92


Mr. R. A. Hruby, General Manager Technical Services WBN Unit Two Watts Bar Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City Tennessee 37381
===Enclosure:===
Inspection Report 05000391/2014611 w/Attachment


Mr. James O'Dell, Manager Licensing and Industry Affairs WBN Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City, Tennessee 37381 Mr. Joseph P. Grimes
REGION II==
Docket No:


Chief Nuclear Officer and Executive Vice President Tennessee Valley Authority
50-391


1101 Market Place 3R Lookout Place Chattanooga, Tennessee 37402-2801
Construction Permit No:
CPPR-92


County Executive
Report No.:


375 Church Street Suite 215 Dayton, Tennessee 37321
05000391/2014611


Mr. Dave Gronek Plant Manager, WBN Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City, Tennessee 37381
Applicant:


Mr. R. R. Baron, Senior Manager Nuclear Construction Quality Assurance WBN Unit Two Watts Bar Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City, Tennessee 37381
Tennessee Valley Authority (TVA)


Mr. Joseph Shea, Vice President Nuclear Licensing Tennessee Valley Authority
Facility:


1101 Market Street
Watts Bar Nuclear Plant, Unit 2  
 
3R Lookout Place
 
Chattanooga, TN 37402-2801 Mr. E. J. Vigluicci Assistant General Counsel Tennessee Valley Authority
 
400 West Summit Hill Drive 6A West Tower Knoxville, Tennessee 37402
 
Mr. Lawrence E. Nanney, Director Tennessee Department of Environmental
 
Health & Conservation Division of Radiological Health 3rd Floor, L&C Annex
 
401 Church Street
 
Nashville, TN 37243-1532
 
Mr. Chris Church Site Vice President Watts Bar Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City, Tennessee 37381 County Mayor P.O. Box 156 Decatur, Tennessee 37322
 
Ms. Ann P. Harris Public 341 Swing Loop
 
Rockwood, TN 37854 cc email distribution w/encl:
 
Greg Scott Tennessee Valley Authority Electronic Mail Distribution
 
Watts Bar 2 Licensing Tennessee Valley Authority Electronic Mail Distribution
 
Letter to Michael from Robert C. Haag dated May 15, 2014.
 
WATTS BAR NUCLEAR PLANT UNIT 2 CONSTRUCTION - NRC PROBLEM IDENTIFICATION AND RESOLUTI ON INSPECTION REPORT 05000391/2014611
 
Distribution w/encl
: Region II Regional Coordinator, OEDO J. Quichocho, NRR


J. Poole, NRR A. Hon, NRR J. Dion, NRR V. McCree, RII L. Douglas, RII EICS
Location:


J. Bartley, RII DRP R. Monk, RII WBN Unit 1 SRI OE Mail ConE_Resource@nrc.gov PUBLIC Enclosure U.S. NUCLEAR REGULATORY COMMISSION REGION II Docket No: 50-391
1260 Nuclear Plant Rd Spring City TN 37381


Construction Permit No: CPPR-92
Inspection Dates:  


Report No.: 05000391/2014611 Applicant: Tennessee Valley Authority (TVA)
April 21 through April 25, 2014


Facility: Watts Bar Nuclear Plant, Unit 2
Inspectors:  


Location: 1260 Nuclear Plant Rd Spring City TN 37381
A. Wilson, (Lead) Construction Project Inspector J. Baptist, Senior Construction Project Inspector D. Harmon, Construction Project Inspector E. Patterson, Construction Resident Inspector K. Steddenbenz, Construction Inspector C. Taylor, Senior Construction Project Inspector S. Temple, Construction Inspector


Inspection Dates: April 21 through April 25, 2014
Approved By:  


Inspectors: A. Wilson, (Lead) Construction Project Inspector J. Baptist, Senior Construction Project Inspector D. Harmon, Construction Project Inspector E. Patterson, Construction Resident Inspector K. Steddenbenz, Construction Inspector C. Taylor, Senior Construction Project Inspector S. Temple, Construction Inspector
Robert C. Haag, Chief Construction Projects Branch 3 Division of Construction Projects  
 
Approved By: Robert C. Haag, Chief Construction Projects Branch 3 Division of Construction Projects  


=EXECUTIVE SUMMARY=
=EXECUTIVE SUMMARY=
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NRC Inspection Report 05000391/2014611  
NRC Inspection Report 05000391/2014611  


Introduction This inspection assessed implementation of the corrective action program for the Watts Bar Unit 2 construction completion project. The inspection program for Unit 2 construction activities is described in NRC Inspection Manual Chapter 2517. Information regarding the Watts Bar Unit 2 Construction Project and NRC inspections can be found at http://www.nrc.gov/info-finder/reactor/wb/watts-bar/construction-insp-info.html. Inspection Results
Introduction  
 
This inspection assessed implementation of the corrective action program for the Watts Bar Unit 2 construction completion project. The inspection program for Unit 2 construction activities is described in NRC Inspection Manual Chapter 2517. Information regarding the Watts Bar Unit 2 Construction Project and NRC inspections can be found at http://www.nrc.gov/info-finder/reactor/wb/watts-bar/construction-insp-info.html.
 
Inspection Results
* In general, the threshold for initiating problem evaluation reports (PERs) was low and PERs were appropriately categorized. For the majority of PERs reviewed, the inspectors determined that problem evaluations were effective in identifying corrective actions that addressed the problem. [Section Q.1.1]
* In general, the threshold for initiating problem evaluation reports (PERs) was low and PERs were appropriately categorized. For the majority of PERs reviewed, the inspectors determined that problem evaluations were effective in identifying corrective actions that addressed the problem. [Section Q.1.1]
* The inspectors determined that adequate measures have been established to evaluate and incorporate applicable operating experience into the corrective action program.
* The inspectors determined that adequate measures have been established to evaluate and incorporate applicable operating experience into the corrective action program.


[Section Q.1.1]
[Section Q.1.1]
* The inspectors determined that TVA and Bechtel have established an acceptable program and environment for allowing employees to identify quality or safety-related concerns. [Section Q.1.1]
* The inspectors determined that TVA and Bechtel have established an acceptable program and environment for allowing employees to identify quality or safety-related concerns. [Section Q.1.1]  
Table of Contents I. QUALITY ASSURANCE PROGRAM ..................................................................................... 5 Q.1 Quality Assurance Program Implementation ................................................................. 5 Q.1.1 Implementation of Corrective Action Program During Construction (IP 35007) ............... 5 V. MANAGEMENT MEETINGS .............................................................................................. 7 X.1 Exit Meeting Summary ..................................................................................................... 7
 
Table of Contents I. QUALITY ASSURANCE PROGRAM..................................................................................... 5 Q.1 Quality Assurance Program Implementation................................................................. 5 Q.1.1 Implementation of Corrective Action Program During Construction (IP 35007)............... 5 V. MANAGEMENT MEETINGS.............................................................................................. 7 X.1 Exit Meeting Summary..................................................................................................... 7


=REPORT DETAILS=
=REPORT DETAILS=
Line 145: Line 116:
The inspectors assessed the adequacy of the Tennessee Valley Authority (TVA) and Bechtel program for identification, evaluation, and corrective action of conditions adverse to quality during the period since the previous problem identification and resolution inspection in April 2013. This was accomplished by reviewing selected PERs, verifying corrective actions were implemented and attending meetings where PERs were screened for significance to determine whether the licensee was identifying, accurately characterizing, and entering problems into the Corrective Action Program (CAP) at an appropriate threshold.
The inspectors assessed the adequacy of the Tennessee Valley Authority (TVA) and Bechtel program for identification, evaluation, and corrective action of conditions adverse to quality during the period since the previous problem identification and resolution inspection in April 2013. This was accomplished by reviewing selected PERs, verifying corrective actions were implemented and attending meetings where PERs were screened for significance to determine whether the licensee was identifying, accurately characterizing, and entering problems into the Corrective Action Program (CAP) at an appropriate threshold.


The inspectors reviewed a sample of PERs and Service Requests (SRs) selected from the applicant's CAP for Watts Bar Unit 2. The sample included problems addressed by a diverse selection of plant departments and problems classified under all of the significance levels. The sample also covered a diverse selection of sources, including problems identified in audits and assessments, nonconforming results from inspections and tests, findings from NRC inspections, concerns from anonymous sources, and concerns identified as adverse trends. Most PERs were reviewed after corrective actions had been implemented; however, some were reviewed after the corrective action plan was developed but prior to implementation.
The inspectors reviewed a sample of PERs and Service Requests (SRs) selected from the applicants CAP for Watts Bar Unit 2. The sample included problems addressed by a diverse selection of plant departments and problems classified under all of the significance levels. The sample also covered a diverse selection of sources, including problems identified in audits and assessments, nonconforming results from inspections and tests, findings from NRC inspections, concerns from anonymous sources, and concerns identified as adverse trends. Most PERs were reviewed after corrective actions had been implemented; however, some were reviewed after the corrective action plan was developed but prior to implementation.


The inspectors also reviewed the applicant's alternate issue tracking systems that address issues that were not classified as conditions adverse to quality. This review targeted verification of appropriate characterization and closure of issues managed outside the corrective action program. The alternative issue tracking systems that were sampled included Test Deficiency Notices (TDNs) and Quality Control (QC) Rejects.
The inspectors also reviewed the applicants alternate issue tracking systems that address issues that were not classified as conditions adverse to quality. This review targeted verification of appropriate characterization and closure of issues managed outside the corrective action program. The alternative issue tracking systems that were sampled included Test Deficiency Notices (TDNs) and Quality Control (QC) Rejects.


These systems were defined as corrective Work Processes approved to track/implement correction, according to TVA's CAP procedure (NC-PP-3, Revision 15).
These systems were defined as corrective Work Processes approved to track/implement correction, according to TVAs CAP procedure (NC-PP-3, Revision 15).


The inspectors reviewed applicable portions of TVA's and Bechtel's Quality Assurance Program (QAP) implementing procedures in order to ensure that commitments for the identification, evaluation, and resolution of conditions adverse to quality had been adequately addressed. The inspectors' review evaluated the applicant's consideration for extent of condition, generic implications, common cause and previous occurrences (trending), including the identification of root and contributing causes along with actions to prevent recurrence for significant conditions adverse to quality.
The inspectors reviewed applicable portions of TVAs and Bechtels Quality Assurance Program (QAP) implementing procedures in order to ensure that commitments for the identification, evaluation, and resolution of conditions adverse to quality had been adequately addressed. The inspectors review evaluated the applicants consideration for extent of condition, generic implications, common cause and previous occurrences (trending), including the identification of root and contributing causes along with actions to prevent recurrence for significant conditions adverse to quality.


The inspectors reviewed TVA's and Bechtel's respective programs for resolving employee concerns. The inspectors interviewed TVA and the major contractor's (Bechtel) employee concern representatives, reviewed a sample of PERs referred to employee concerns and PERs initiated as a result of employee concerns. The inspectors also reviewed several anonymous PERs to determine if they had been adequately captured and addressed. The inspectors reviewed and evaluated the adequacy of the programs, which provide employees with an alternate method to identify quality or safety-related concerns. The inspectors also reviewed surveys and assessments of the employee concerns programs.
The inspectors reviewed TVAs and Bechtels respective programs for resolving employee concerns. The inspectors interviewed TVA and the major contractors (Bechtel) employee concern representatives, reviewed a sample of PERs referred to employee concerns and PERs initiated as a result of employee concerns. The inspectors also reviewed several anonymous PERs to determine if they had been adequately captured and addressed. The inspectors reviewed and evaluated the adequacy of the programs, which provide employees with an alternate method to identify quality or safety-related concerns. The inspectors also reviewed surveys and assessments of the employee concerns programs.


The inspectors reviewed a sample of the applicant's management and quality assessments, audits, and trend reports to verify adverse results were properly evaluated and dispositioned within the corrective action program. The inspectors reviewed the revision history for corrective action program implementing procedures and assessed the integration of industry operating experience into the corrective action process. Direct observations by inspectors included meetings of the Project Review Committee (PRC) and the Construction Completion Management Review Committee (CCMRC) as they screened newly reported problems and reviewed dispositions for selected issues.
The inspectors reviewed a sample of the applicants management and quality assessments, audits, and trend reports to verify adverse results were properly evaluated and dispositioned within the corrective action program. The inspectors reviewed the revision history for corrective action program implementing procedures and assessed the integration of industry operating experience into the corrective action process. Direct observations by inspectors included meetings of the Project Review Committee (PRC)and the Construction Completion Management Review Committee (CCMRC) as they screened newly reported problems and reviewed dispositions for selected issues.


Specific PERs and other documents reviewed are listed in the attachment.
Specific PERs and other documents reviewed are listed in the attachment.
Line 163: Line 134:


The inspectors made the following observations as a result of their inspections:
The inspectors made the following observations as a result of their inspections:
: (1) Effectiveness of Identifying, Evaluating, and Correcting Problems Identifying Problems
: (1) Effectiveness of Identifying, Evaluating, and Correcting Problems  
 
Identifying Problems  


The inspectors determined that, for the most part, the applicant was effective in identifying problems and entering them into the CAP. PERs normally provided complete and accurate characterization of the subject issues. Employees were encouraged by management to initiate PERs.
The inspectors determined that, for the most part, the applicant was effective in identifying problems and entering them into the CAP. PERs normally provided complete and accurate characterization of the subject issues. Employees were encouraged by management to initiate PERs.


Evaluating Problems The inspectors attended several meetings throughout the week, including the PRC and the CCMRC. It was determined that the applicant had adequately prioritized issues entered into the CAP consistent with established procedures. SRs that were being initiated and discussed during the meetings were being appropriately dispositioned. The inspectors determined that the threshold of closing items as SRs, closing items to a work order (WO), and creating a PER when necessary was adequate.
Evaluating Problems  


Correcting Problems
The inspectors attended several meetings throughout the week, including the PRC and the CCMRC. It was determined that the applicant had adequately prioritized issues entered into the CAP consistent with established procedures. SRs that were being initiated and discussed during the meetings were being appropriately dispositioned. The inspectors determined that the threshold of closing items as SRs, closing items to a work order (WO), and creating a PER when necessary was adequate.


Based on a review of numerous PER corrective actions and their implementation, the team found, for the most part, that the applicant's corrective actions developed and implemented for problems were commensurate with the safety significance of the issues.
Correcting Problems
 
Based on a review of numerous PER corrective actions and their implementation, the team found, for the most part, that the applicants corrective actions developed and implemented for problems were commensurate with the safety significance of the issues.
: (2) Use of Operating Experience  
: (2) Use of Operating Experience  


The inspectors determined that the applicant's measures used to identify, evaluate and incorporate applicable industry and operating experience (I&OE) information into the corrective action program contained processes for including vendor recommendations and internally generated lessons learned. The I&OE information was collected, evaluated, and communicated to the affected internal stakeholders as specified in TVA and Bechtel procedures. The inspectors determined that appropriate corrective actions were developed and taken for the sample of I&OE problem evaluation reports reviewed for the Watts Bar Unit 2 Construction Completion Project.
The inspectors determined that the applicants measures used to identify, evaluate and incorporate applicable industry and operating experience (I&OE) information into the corrective action program contained processes for including vendor recommendations and internally generated lessons learned. The I&OE information was collected, evaluated, and communicated to the affected internal stakeholders as specified in TVA and Bechtel procedures. The inspectors determined that appropriate corrective actions were developed and taken for the sample of I&OE problem evaluation reports reviewed for the Watts Bar Unit 2 Construction Completion Project.
: (3) Safety Conscious Work Environment (SCWE)
: (3) Safety Conscious Work Environment (SCWE)  
The inspectors reviewed several anonymous PERs and PERs that either referred to the employee concerns program (ECP) or PERs generated as a result of employee concerns. Employees interviewed expressed knowledge of the employee concerns program and the ability to raise safety related concerns through various available means. The inspectors also interviewed senior employee concerns coordinators from both TVA and Bechtel. The inspectors determined that TVA's and Bechtel's employee concern programs were adequate. The senior employee concerns coordinators expressed knowledge of the ECP and the ability to raise safety related concerns through various available means. The inspectors noted that the ECP staff provide several training sessions, they provide ECP information in newsletters, and they also walk around the site frequently, talk daily to staff, and attend several meetings to ensure that staff are aware of the ECP and know how to raise concerns if necessary. Also, there appeared to be strong management support for both the Bechtel and TVA ECP.
 
: (4) Corrective Action Program Performance Insights The sample of audits, assessments, and surveillances reviewed by the inspectors confirmed that management and quality pers onnel actively conducted observations and effectiveness reviews of the corrective action program. These program assessments concluded that overall, the corrective action program was effectively implemented. The applicant continues to track and trend issues, run summary reports on the trend data, and present results to management in several meetings, such as the site status meeting, CCMRC, etc.
The inspectors reviewed several anonymous PERs and PERs that either referred to the employee concerns program (ECP) or PERs generated as a result of employee concerns. Employees interviewed expressed knowledge of the employee concerns program and the ability to raise safety related concerns through various available means. The inspectors also interviewed senior employee concerns coordinators from both TVA and Bechtel. The inspectors determined that TVAs and Bechtels employee concern programs were adequate. The senior employee concerns coordinators expressed knowledge of the ECP and the ability to raise safety related concerns through various available means. The inspectors noted that the ECP staff provide several training sessions, they provide ECP information in newsletters, and they also walk around the site frequently, talk daily to staff, and attend several meetings to ensure that staff are aware of the ECP and know how to raise concerns if necessary. Also, there appeared to be strong management support for both the Bechtel and TVA ECP.
: (4) Corrective Action Program Performance Insights  
 
The sample of audits, assessments, and surveillances reviewed by the inspectors confirmed that management and quality personnel actively conducted observations and effectiveness reviews of the corrective action program. These program assessments concluded that overall, the corrective action program was effectively implemented. The applicant continues to track and trend issues, run summary reports on the trend data, and present results to management in several meetings, such as the site status meeting, CCMRC, etc.
: (5) Corrective Action Program Effectiveness  
: (5) Corrective Action Program Effectiveness  


As discussed above, in general, the applicant's CAP was effective and adequate. The inspectors determined that the applicant has maintained implementation of the CAP at an effective level since the last NRC PI&R inspection (April 2013).
As discussed above, in general, the applicants CAP was effective and adequate. The inspectors determined that the applicant has maintained implementation of the CAP at an effective level since the last NRC PI&R inspection (April 2013).


====c. Conclusions====
====c. Conclusions====
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In regards to maintaining a Safety Conscious Work Environment, the inspectors determined that TVA and Bechtel had established an acceptable program and environment for allowing employees to identify quality or safety-related concerns.
In regards to maintaining a Safety Conscious Work Environment, the inspectors determined that TVA and Bechtel had established an acceptable program and environment for allowing employees to identify quality or safety-related concerns.


V. Management Meetings
V.


X.1 
Management Meetings


=====Exit Meeting Summary=====
X.1
 
===Exit Meeting Summary===
On April 25, 2014, the inspectors presented the inspection results to you and other members of your staff. Proprietary information reviewed during the inspection was returned and no proprietary information was included in this inspection report.
On April 25, 2014, the inspectors presented the inspection results to you and other members of your staff. Proprietary information reviewed during the inspection was returned and no proprietary information was included in this inspection report.


Line 197: Line 177:


Partial List of Persons Contacted
Partial List of Persons Contacted
Applicant personnel
Applicant personnel  
: [[contact::D. Charlton]], TVA - Licensing  
: [[contact::D. Charlton]], TVA - Licensing  
: [[contact::T. Cheek]], TVA - CAP Manager  
: [[contact::T. Cheek]], TVA - CAP Manager  
: [[contact::M. Cooper]], TVA - CAP Oversight  
: [[contact::M. Cooper]], TVA - CAP Oversight  
: [[contact::B. Gillham]], TVA - Licensing  
: [[contact::B. Gillham]], TVA - Licensing  
: [[contact::B. Heinmiller]], Bechtel - CAP Manager
: [[contact::B. Heinmiller]], Bechtel - CAP Manager  
: [[contact::Y. Hink]], Bechtel - Employee Concerns  
: [[contact::Y. Hink]], Bechtel - Employee Concerns  
: [[contact::R. Kirckpatrick]], TVA - Engineering  
: [[contact::R. Kirckpatrick]], TVA - Engineering  
: [[contact::T. Niessen]], TVA Audits & Assessment Manager  
: [[contact::T. Niessen]], TVA Audits & Assessment Manager  
: [[contact::J. O'Dell]], TVA - Regulatory Compliance  
: [[contact::J. ODell]], TVA - Regulatory Compliance  
: [[contact::L. Reaves]], TVA - Employee Concerns  
: [[contact::L. Reaves]], TVA - Employee Concerns  
: [[contact::K. Rose]], Bechtel - CAP Coordinator  
: [[contact::K. Rose]], Bechtel - CAP Coordinator  
Line 214: Line 194:


Inspection Procedure Used
Inspection Procedure Used
IP 35007 Quality Assurance Program Implementation during Construction  
IP 35007
Quality Assurance Program Implementation during Construction  


List of Items Opened, Closed, and Discussed
List of Items Opened, Closed, and Discussed
Opened
Opened
None
None  
 
Opened and Closed
Opened and Closed
None
None  
 
Discussed
Discussed
None
None  
 
List of Documents Reviewed
List of Documents Reviewed
Problem Evaluation Reports
Problem Evaluation Reports
2178 Trend in Red-Line Process Issues 394793 Ineffective Preventive Actions Associated with PER 262178
2178
581841 ASME Non-conformance
Trend in Red-Line Process Issues
615657 Improvements Needed to Prevent Recurrence of Missed QC Holdpoints
394793
706129 Potential problem with Westinghouse ARD relays for DC application
Ineffective Preventive Actions Associated with PER 262178
708450 NRC Id'd: Hardware Non-Conformance for HVAC Support in Closed WO 709036 Anonymous PER: Hostile Work Environment 709637 Multiplication Error in Rosemount 1152 Calculation
581841
713135 ASME Hardware Non-Conformance DRAVO Spool S/N 11450 Historic Issue
ASME Non-conformance
713742 PER closure - QA Assessment NC-WB-13-006
615657
715564 NRC Id-d: Upper Lateral Support Material Not Tested In Accordance with Requirements 724028 WO 110932752 does not provide adequate precautions for work on ABSCE support
Improvements Needed to Prevent Recurrence of Missed QC Holdpoints
25478 ASME III Hardware Non-Conformance.Sys 030/067 Indication On Piping For WBN-2-Ccu-030-0078-B 735081 Hardware Non-Conformance: QA3 Mat'l Used In QA1 Application. Sys 3, 61, 62, 63, 68, 70, 72 738567 Missing cross reference for PER to WO
706129
738580 Work not completed to address non-conforming condition
Potential problem with Westinghouse ARD relays for DC application
739613 Evaluate Westinghouse TB-13-1 applicability to WBN2.
708450
741744 Historical: Wood insulation discovered in ice condenser personnel access door
NRC Id'd: Hardware Non-Conformance for HVAC Support in Closed WO
2527 CCE, SYS WBN063, WBN-2-3VC-293-6044-B, Conduit exceeds 360° bends with cable pulled in 742574 Unit 2 construction radiography. Weld 2-062B-D139-27 C1R0; metallic debris in pipe
709036
743615 Adverse Trend for By-passed ANI/QC Holdpoints, Witness points, reviews, and
Anonymous PER: Hostile Work Environment
notifications 745899 Supplier Quality Rep, personnel qualification records are not in EDMS 748557 Common Q Panels may not have properly adjusted retaining angle brackets for
709637
seismic event 750214 Anonymous PER: Bechtel Supervisor rushing craft to the field w/o proper paperwork
Multiplication Error in Rosemount 1152 Calculation
753260 ASME related: Failure to follow procedure MGT-0003
713135
754455 A Dye Penetrant Exam Of Weld# 2-063b-T071-28-C0r0, Revealed A 3-1/2" Linear Indication In The Pipe 754469 ASME Related, Errors in PCI Documents (RTD Bypass) Found During Final Review 756990 Potentially Reportable Hardware Non-Conformance: 10 CFR Part 21 notification
ASME Hardware Non-Conformance DRAVO Spool S/N 11450 Historic Issue
763291 Pressurizer PORV Cv Design Change
713742
766429 Errors in WBNTSR008 calculation
PER closure - QA Assessment NC-WB-13-006
766488 Anonymous PER: Issues with FCR approval process 777477 Personal documenting approval of ASME Section III Design Specification not adequately qualified 781458 QA identified Adverse Trend in CAP Action Closure Quality
715564
788677 Anonymous PER: Work orders have recurring problems
NRC Id-d: Upper Lateral Support Material Not Tested In Accordance with
790185 Unauthorized Rework on Flex Conduit 800044
Requirements
790717 Review of WO#110990376 R1 CCE, SY
24028
WO 110932752 does not provide adequate precautions for work on ABSCE support
25478
ASME III Hardware Non-Conformance.Sys 030/067 Indication On Piping For
WBN-2-Ccu-030-0078-B
735081
Hardware Non-Conformance: QA3 Mat'l Used In QA1 Application. Sys 3, 61, 62, 63,
68, 70, 72
738567
Missing cross reference for PER to WO
738580
Work not completed to address non-conforming condition
739613
Evaluate Westinghouse TB-13-1 applicability to WBN2.
741744
Historical: Wood insulation discovered in ice condenser personnel access door
2527
CCE, SYS WBN063, WBN-2-3VC-293-6044-B, Conduit exceeds 360° bends with
cable pulled in
2574
Unit 2 construction radiography. Weld 2-062B-D139-27 C1R0; metallic debris in pipe
743615
Adverse Trend for By-passed ANI/QC Holdpoints, Witness points, reviews, and
notifications
745899
Supplier Quality Rep, personnel qualification records are not in EDMS
748557
Common Q Panels may not have properly adjusted retaining angle brackets for
seismic event
750214
Anonymous PER: Bechtel Supervisor rushing craft to the field w/o proper paperwork
753260
ASME related: Failure to follow procedure MGT-0003
754455
A Dye Penetrant Exam Of Weld# 2-063b-T071-28-C0r0, Revealed A 3-1/2" Linear
Indication In The Pipe
754469
ASME Related, Errors in PCI Documents (RTD Bypass) Found During Final Review
756990
Potentially Reportable Hardware Non-Conformance: 10 CFR Part 21 notification
763291
Pressurizer PORV Cv Design Change
766429
Errors in WBNTSR008 calculation
766488
Anonymous PER: Issues with FCR approval process
777477
Personal documenting approval of ASME Section III Design Specification not
adequately qualified
781458
QA identified Adverse Trend in CAP Action Closure Quality
788677
Anonymous PER: Work orders have recurring problems
790185
Unauthorized Rework on Flex Conduit 800044
790717
Review of WO#110990376 R1 CCE, SY
: [[contact::S. WBN074]], and WBN063 associated
: [[contact::S. WBN074]], and WBN063 associated
commodities 790722 Incorrect dimensions not identified on FCR 61876 AA-02
commodities
790730 ASME: Missing dates for approval/concurrence reviews for Supplier Quality
790722
Procedure and Manual
Incorrect dimensions not identified on FCR 61876 AA-02
791834 FCR written to document As-built condition of installation does not match layout
790730
piping DRA 793461 Work Order Signatures 794620 ASME WO 111059418 was closed without obtaining N-5 and ANI final review as
ASME: Missing dates for approval/concurrence reviews for Supplier Quality
required by N1206 794668 Vendor Heat Loss Calculation for Metal Reflective Insulation Does Not Match Design
Procedure and Manual  
Drawings 800044 NRC Identified, Potential Over Torque of Wrapper Plug Assembly
 
800570 Unit 2, 2-FCV-070-0087 MOV actuator mounting hardware is not correct 802311 ASME WO 115220992 WBN-2-CKV-062-0532-B SENSITIZATION 804263 ASME System WBN068 Issues found with Archived PER 215474 & BIT 1405
791834
807454 Instrumentation tubing sulfur content outside acceptable values for orbital welding
FCR written to document As-built condition of installation does not match layout
808623 PRZR instrument nozzle couplings removed
piping DRA
819918 Anonymous PER: Work Orders not Being Worked per Procedures 832473 Cable 2PV6750 in Bend Radius Violation (SYS WBN098) 832928 System WBN067 TIC's may not maintain position retention
793461
834004 Hardware Non-conformance: 3/4" rebar was cut without authorization
Work Order Signatures
838631 ECP Referral: Potential damaged rebar and tube bending tool causing damage to
794620
3/4" SS tubing 842892 Insufficient Clearance Between Valve WBN-2-CKV-063-0634 and Crane Wall 842964 SU Trend PER due to HU incidents at undesirable level
ASME WO 111059418 was closed without obtaining N-5 and ANI final review as
844207 SUT SYS WBN027 TDN 13-446 Time Delay Relays did not meet acceptance Criteria
required by N1206
844218 NRC Identified: Unit 2 Rack 2 Narrow Range RTD WO 113471100 PMT Data
794668
844222 TDN Trending and Processing Errors
Vendor Heat Loss Calculation for Metal Reflective Insulation Does Not Match Design
844234 NRC Identified - Valve data sheets reference incorrect material specification 845228 System WBN063 Potential Proximity Interactions 850485 Pipefitter performed unauthorized work
Drawings
851810 During disassembly of the 2A Safety Injection Pump, multiple deficiencies were identified 857648 Anonymous PER: Craft Being Pushed to Work Fast in an Unsafe Manner 857667 ASME Section III Components - Trend PER - assembly quality issues with OEM
800044
Flowserve 861461 PER 469477 and PER 708506 have been closed without all actions being
NRC Identified, Potential Over Torque of Wrapper Plug Assembly
completed/addressed as required 863840 SUTR SYS WBN062 WBN-2-GR-062-0108-A
800570
875435 Administrative Closure Issues Found during and Engineering Review of Closed PERs 872509 Incorrect wire installed on the output side of Temperature Modulators
Unit 2, 2-FCV-070-0087 MOV actuator mounting hardware is not correct 802311
875435 Administrative Closure Issues Found during an Engineering Review of Closed PERs
ASME WO 115220992 WBN-2-CKV-062-0532-B SENSITIZATION
876414 Missing 18 inch mirror insulation at Acc room #3,el. 702' Az 180, SIS piping
804263
877650 CCM SYS WBN040 UNID-2-PIPE-040-G. Nail identified inside RCP 4 oil drain line
ASME System WBN068 Issues found with Archived PER 215474 & BIT 1405
on E
807454
: [[contact::L. 716 877665 PI&R NRC ID'd: ASME Code III Hardware SRs closed to work performed]], rather than going to a PER
Instrumentation tubing sulfur content outside acceptable values for orbital welding
808623
PRZR instrument nozzle couplings removed
819918
Anonymous PER: Work Orders not Being Worked per Procedures
2473
Cable 2PV6750 in Bend Radius Violation (SYS WBN098)
2928
System WBN067 TIC's may not maintain position retention
834004
Hardware Non-conformance: 3/4" rebar was cut without authorization
838631
ECP Referral: Potential damaged rebar and tube bending tool causing damage to
3/4" SS tubing
2892
Insufficient Clearance Between Valve WBN-2-CKV-063-0634 and Crane Wall
2964
SU Trend PER due to HU incidents at undesirable level
844207
SUT SYS WBN027 TDN 13-446 Time Delay Relays did not meet acceptance Criteria
844218
NRC Identified: Unit 2 Rack 2 Narrow Range RTD WO 113471100 PMT Data
844222
TDN Trending and Processing Errors
844234
NRC Identified - Valve data sheets reference incorrect material specification
845228
System WBN063 Potential Proximity Interactions
850485
Pipefitter performed unauthorized work
851810
During disassembly of the 2A Safety Injection Pump, multiple deficiencies were
identified
857648
Anonymous PER: Craft Being Pushed to Work Fast in an Unsafe Manner
857667
ASME Section III Components - Trend PER - assembly quality issues with OEM
Flowserve
861461
PER 469477 and PER 708506 have been closed without all actions being
completed/addressed as required
863840
SUTR SYS WBN062 WBN-2-GR-062-0108-A
875435
Administrative Closure Issues Found during and Engineering Review of Closed
PERs
2509
Incorrect wire installed on the output side of Temperature Modulators
875435
Administrative Closure Issues Found during an Engineering Review of Closed PERs
876414
Missing 18 inch mirror insulation at Acc room #3,el. 702' Az 180, SIS piping
877650
CCM SYS WBN040 UNID-2-PIPE-040-G. Nail identified inside RCP 4 oil drain line
on EL. 716
877665
PI&R NRC ID'd: ASME Code III Hardware SRs closed to work performed, rather
than going to a PER
Service Requests
Service Requests
695055 Existing Root Valve 2-RTV-062-0442A is not operating smoothly 724339 Loose bolting on 2-RFV-067-0573B-B 724351 Loose bolting on 2-RFV-067-1033A-A, 1029B-b and 2-FE-067-0183
695055
24525 SR closed to WO for ASME item without creating a PER
Existing Root Valve 2-RTV-062-0442A is not operating smoothly
732302 Hardware Non-conformance: QA3 Mat'l used in QA1 Application, SYS 3, 61, 62, 63, 68, 70, 72 739452 Commodity Clearance Violation on HVAC Support 75-4517 739531 ASME Hardware Nonconformance Inadequate Socket Depth of Valves 2-DRV-068-
24339
0557 and -0558 754881 MAI-5.1B requirements were not completed, System WBN293
Loose bolting on 2-RFV-067-0573B-B
780734 QA identified Adverse Trend in CAP Action Closure Quality
24351
787376 Loose Bolting on Relief Valve in Unit 2
Loose bolting on 2-RFV-067-1033A-A, 1029B-b and 2-FE-067-0183
2916 Solenoid Valve top cover bent 807559 Historical Issue: Broken Embedded Ground Cable 836724 ASME Hardware Nonconformance - System 6.1 Indications Violated Min Wall Repair
24525
IAW Bechtel SPM 855583 ASME Section III Components - Trend PER - assembly quality issues with OEM
SR closed to WO for ASME item without creating a PER  
Flowserve 863108 SUTR SYS WBN062 WBN-2-GR-062-0108-A 875013 Administrative Closure Issues Found during and Engineering Review of Closed PERs 875329 CCM SYS WBN040 UNID-2-PIPE-040-G. Nail
 
identified inside RCP 4 oil drain line
2302
on E
Hardware Non-conformance: QA3 Mat'l used in QA1 Application, SYS 3, 61, 62, 63,
: [[contact::L. 716 876118 Missing 18 inch mirror insulation at Acc room #3]],el. 702' Az 180, SIS piping 876378 PI&R NRC ID'd: ASME Code III Hardware SRs closed to work performed, rather than going to a PER
68, 70, 72
739452
Commodity Clearance Violation on HVAC Support 75-4517
739531
ASME Hardware Nonconformance Inadequate Socket Depth of Valves 2-DRV-068-
0557 and -0558
754881
MAI-5.1B requirements were not completed, System WBN293
780734
QA identified Adverse Trend in CAP Action Closure Quality
787376
Loose Bolting on Relief Valve in Unit 2
2916
Solenoid Valve top cover bent
807559
Historical Issue: Broken Embedded Ground Cable
836724
ASME Hardware Nonconformance - System 6.1 Indications Violated Min Wall Repair
IAW Bechtel SPM
855583
ASME Section III Components - Trend PER - assembly quality issues with OEM
Flowserve
863108
SUTR SYS WBN062 WBN-2-GR-062-0108-A
875013
Administrative Closure Issues Found during and Engineering Review of Closed
PERs
875329
CCM SYS WBN040 UNID-2-PIPE-040-G. Nail identified inside RCP 4 oil drain line
on EL. 716
876118
Missing 18 inch mirror insulation at Acc room #3,el. 702' Az 180, SIS piping
876378
PI&R NRC ID'd: ASME Code III Hardware SRs closed to work performed, rather
than going to a PER
Test Deficiency Notices
Test Deficiency Notices
13-217 2-HS-67-111C hand switch does not operate valve, no continuity in switch contact circuit 13-244 Torque switch operation is suspect
13-217
13-280 Max seating/unseating est motor torques exceeds limit on design rwg
2-HS-67-111C hand switch does not operate valve, no continuity in switch contact
13-281 Running average est motor torques exceeds limit on design rwg
circuit
13-338 Fuses are blowing after long delay 13-361 No seating torque on MOVATS; suspect not tightly closed 13-390 MEL data is not filled out correctly
13-244
13-486 High running load during MOVATS test
Torque switch operation is suspect
13-505 Packing/running load exceeded
13-280
13-515 High running load during MOVATS test
Max seating/unseating est motor torques exceeds limit on design rwg
13-525 Diode in JB 1910 is installed in the reverse direction 13-526 Diode in JB 1910 is installed in the reverse direction 14-046 High packing/running load
13-281
14-058 Packing/running load exceeded
Running average est motor torques exceeds limit on design rwg
14-108 Wiring issue. DRA does not match Cat 1 drawing
13-338
14-204 Unclear design output for valve stroke time requirements
Fuses are blowing after long delay
13-361
No seating torque on MOVATS; suspect not tightly closed
13-390
MEL data is not filled out correctly
13-486
High running load during MOVATS test
13-505
Packing/running load exceeded
13-515
High running load during MOVATS test
13-525
Diode in JB 1910 is installed in the reverse direction
13-526
Diode in JB 1910 is installed in the reverse direction
14-046
High packing/running load
14-058
Packing/running load exceeded
14-108
Wiring issue. DRA does not match Cat 1 drawing
14-204
Unclear design output for valve stroke time requirements
Procedures and Programs
Procedures and Programs
25402-MGT-000, "Corrective Action Program," Rev. 16
25402-MGT-000, Corrective Action Program, Rev. 16
25402-MGT-0004, "Incident Investigation and Root Cause Analysis," Rev. 4
25402-MGT-0004, Incident Investigation and Root Cause Analysis, Rev. 4
25402-000-GPP-0000-N3702, "Arc Strike Removal / Base Metal Repair of Piping / Components and Structural / Miscellaneous Steel," Rev. 2 25402-00-GPP-0000-N1206, "Work Order Processing," Rev. 18 NC-PP-3, "Watts Bar Unit 2 Corrective Action Program," Rev. 15
25402-000-GPP-0000-N3702, Arc Strike Removal / Base Metal Repair of Piping / Components
NC-PP-8, "Watts Bar Unit 2 Operating Experience / Construction Experience Plan," Rev. 2
and Structural / Miscellaneous Steel, Rev. 2
NC-PP-6, "Completion of TVA NC Partial ASME Section III Division 1 N-5 Data Reports",
25402-00-GPP-0000-N1206, "Work Order Processing," Rev. 18
Rev. 13 NPG-SPP-06.4, "Measuring and Test Equipment," Rev. 2
NC-PP-3, Watts Bar Unit 2 Corrective Action Program, Rev. 15
NC-PP-8, Watts Bar Unit 2 Operating Experience / Construction Experience Plan, Rev. 2
NC-PP-6, Completion of TVA NC Partial ASME Section III Division 1 N-5 Data Reports,  
 
Rev. 13
NPG-SPP-06.4, Measuring and Test Equipment, Rev. 2
Audit Reports
Audit Reports
Audit Report No. NC1302, "Corrective Action Program," dated 6/26/13
Audit Report No. NC1302, Corrective Action Program, dated 6/26/13
Bechtel Audit No. 25402-WBN-AR13-0002, "Bechtel Quality Assurance Manuals," Rev. 0
Bechtel Audit No. 25402-WBN-AR13-0002, Bechtel Quality Assurance Manuals, Rev. 0
Quality Assurance Assessment Report NC-WB-13-006, "Problem Evaluation Report Closures," dated 4/18/13
Quality Assurance Assessment Report NC-WB-13-006, Problem Evaluation Report Closures,
dated 4/18/13  
 
Miscellaneous
Miscellaneous
2013 Assessment of WB2 Safety Conscious
2013 Assessment of WB2 Safety Conscious Work Environment and Safety Culture
Work Environment and Safety Culture Bechtel Annual SCWE Pulsing Survey; 2012 and 2013 Results Comparison
Bechtel Annual SCWE Pulsing Survey; 2012 and 2013 Results Comparison
Bechtel CAP Status Report, dated February 2014 Bechtel Employee Concerns Cases Associated with PERs; 04/01/2013 through 04/23/2014 CAP Trend Report; March 2014
Bechtel CAP Status Report, dated February 2014
Bechtel Employee Concerns Cases Associated with PERs; 04/01/2013 through 04/23/2014
CAP Trend Report; March 2014
Test Deficiency Notice Trending; 03/19/2014 through 04/17/2014
Test Deficiency Notice Trending; 03/19/2014 through 04/17/2014
Watts Bar Nuclear Plant U1/U2 Corrective Action Program Transition Strategy Document
Watts Bar Nuclear Plant U1/U2 Corrective Action Program Transition Strategy Document
WBC ECP Pulsing Results; Completed 10/23/2013 WBC ECP Pulsing Results; Completed 03/27/2014 WBN U2 CAP Metrics Report, dated February 2014
WBC ECP Pulsing Results; Completed 10/23/2013
WBN U2 CAP Self-Assessment WBN2-CAP-14-1, dated 3/25/14  
WBC ECP Pulsing Results; Completed 03/27/2014
 
WBN U2 CAP Metrics Report, dated February 2014
Drawing 2-45B2768-11E, Rev. 7 2-47A8910-63-01, Rev. 2
WBN U2 CAP Self-Assessment WBN2-CAP-14-1, dated 3/25/14
Drawing
2-45B2768-11E, Rev. 7
2-47A8910-63-01, Rev. 2
Calculation
Calculation
MDQ0020632008-0229, Rev. 003
MDQ0020632008-0229, Rev. 003
Field Change Requests
Field Change Requests
FCR 60603-A, DRA No. 5331-168, -190, -408, and -409, Rev. 0
FCR 60603-A, DRA No. 5331-168, -190, -408, and -409, Rev. 0
FCR 59905-A, AA-07, dated 8/1/12  
FCR 59905-A, AA-07, dated 8/1/12
 
Work Orders
Work Orders
WO 114633238, CCM SYS 067 WBN-2-RFV-067-1033A-A ASME Class 3 WO 115149219, CCM EDCR2 53580 SYS 063 PER 760933 2-RFV-063-0627-B PER 760933 FCR 61757-A AA-09  
WO 114633238, CCM SYS 067 WBN-2-RFV-067-1033A-A ASME Class 3
WO 115149219, CCM EDCR2 53580 SYS 063 PER 760933 2-RFV-063-0627-B PER 760933
FCR 61757-A AA-09  


List of Acronyms
List of Acronyms
ADAMS Agencywide Document Access Management System CAP Corrective Action Program CCMRC Construction Completion Management Review Committee CFR Code of Federal Regulations
ADAMS
ECP Employee Concerns Program
Agencywide Document Access Management System
I&OE Industry and Operating Experience
CAP
IP Inspection Procedure (NRC) NRC Nuclear Regulatory Commission PARS Publicly Available Records
Corrective Action Program
PER Problem Evaluation Report
CCMRC
PI&R Problem Identification and Resolution
Construction Completion Management Review Committee
PRC Project Review Committee
CFR
QA Quality Assurance QAP Quality Assurance Program QC Quality Control
Code of Federal Regulations
SCWE Safety Conscious Work Environment
ECP
SR Service Request
Employee Concerns Program
TDN Test Deficiency Notice TVA Tennessee Valley Authority WBN Watts Bar Nuclear Plant
I&OE
WO Work Order
Industry and Operating Experience
IP
Inspection Procedure (NRC)
NRC
Nuclear Regulatory Commission
PARS
Publicly Available Records
PER
Problem Evaluation Report
PI&R
Problem Identification and Resolution
PRC
Project Review Committee
QA
Quality Assurance
QAP
Quality Assurance Program
QC
Quality Control
SCWE
Safety Conscious Work Environment
SR
Service Request
TDN
Test Deficiency Notice
TVA
Tennessee Valley Authority
WBN
Watts Bar Nuclear Plant
WO
Work Order
}}
}}

Latest revision as of 20:44, 10 January 2025

IR 05000391-14-611, 04/21-25/2014, Watts Bar, Unit 2, Problem Identification and Resolution Inspection
ML14135A428
Person / Time
Site: Watts Bar Tennessee Valley Authority icon.png
Issue date: 05/15/2014
From: Haag R
NRC/RGN-II/DCP/CPB3
To: Skaggs M
Tennessee Valley Authority
Michelle Adams
References
IR-14-611
Download: ML14135A428 (19)
v • d • e


Text

May 15, 2014

SUBJECT:

WATTS BAR NUCLEAR PLANT UNIT 2 CONSTRUCTION - NRC PROBLEM IDENTIFICATION AND RESOLUTION INSPECTION REPORT 05000391/2014611

Dear Mr. Skaggs:

On April 25, 2014, the U.S. Nuclear Regulatory Commission (NRC) completed an inspection of construction activities at your Watts Bar Unit 2 reactor facility. The enclosed inspection report documents the inspection results, which were discussed on April 25, 2013, with you and other members of your staff.

This problem identification and resolution (PI&R) inspection examined activities conducted under your Unit 2 construction permit as they relate to identification and resolution of problems, compliance with the Commissions rules and regulations, and with the conditions of your construction permit. The inspectors reviewed selected procedures and records, observed activities, and interviewed personnel.

No findings were identified during this inspection.

In accordance with 10 Code of Federal Regulations (CFR) 2.390 of the NRCs Rules of Practice, a copy of this letter, its enclosure, and your response (if any) will be available electronically for public inspection in the NRC Public Document Room or from the Publicly Available Records (PARS) component of the NRCs document system (ADAMS). ADAMS is accessible from the NRC Web site at http://www.nrc.gov/reading-rm/adams.html (the Public Electronic Reading Room).

UNITED STATES NUCLEAR REGULATORY COMMISSION

REGION II

245 PEACHTREE CENTER AVENUE NE, SUITE 1200 ATLANTA, GEORGIA 30303-1257 Should you have questions concerning this letter, please contact us.

Sincerely,

/RA/

Robert C. Haag, Chief

Construction Projects Branch 3

Division of Construction Projects

Docket No. 50-391 Construction Permit No: CPPR-92

Enclosure:

Inspection Report 05000391/2014611 w/Attachment

REGION II==

Docket No:

50-391

Construction Permit No:

CPPR-92

Report No.:

05000391/2014611

Applicant:

Tennessee Valley Authority (TVA)

Facility:

Watts Bar Nuclear Plant, Unit 2

Location:

1260 Nuclear Plant Rd Spring City TN 37381

Inspection Dates:

April 21 through April 25, 2014

Inspectors:

A. Wilson, (Lead) Construction Project Inspector J. Baptist, Senior Construction Project Inspector D. Harmon, Construction Project Inspector E. Patterson, Construction Resident Inspector K. Steddenbenz, Construction Inspector C. Taylor, Senior Construction Project Inspector S. Temple, Construction Inspector

Approved By:

Robert C. Haag, Chief Construction Projects Branch 3 Division of Construction Projects

EXECUTIVE SUMMARY

Watts Bar Nuclear Plant, Unit 2

NRC Inspection Report 05000391/2014611

Introduction

This inspection assessed implementation of the corrective action program for the Watts Bar Unit 2 construction completion project. The inspection program for Unit 2 construction activities is described in NRC Inspection Manual Chapter 2517. Information regarding the Watts Bar Unit 2 Construction Project and NRC inspections can be found at http://www.nrc.gov/info-finder/reactor/wb/watts-bar/construction-insp-info.html.

Inspection Results

  • In general, the threshold for initiating problem evaluation reports (PERs) was low and PERs were appropriately categorized. For the majority of PERs reviewed, the inspectors determined that problem evaluations were effective in identifying corrective actions that addressed the problem. [Section Q.1.1]
  • The inspectors determined that adequate measures have been established to evaluate and incorporate applicable operating experience into the corrective action program.

[Section Q.1.1]

  • The inspectors determined that TVA and Bechtel have established an acceptable program and environment for allowing employees to identify quality or safety-related concerns. [Section Q.1.1]

Table of Contents I. QUALITY ASSURANCE PROGRAM..................................................................................... 5 Q.1 Quality Assurance Program Implementation................................................................. 5 Q.1.1 Implementation of Corrective Action Program During Construction (IP 35007)............... 5 V. MANAGEMENT MEETINGS.............................................................................................. 7 X.1 Exit Meeting Summary..................................................................................................... 7

REPORT DETAILS

I. QUALITY ASSURANCE PROGRAM

Q.1 Quality Assurance Program Implementation

Q.1.1 Implementation of Corrective Action Program During Construction (Inspection Procedure 35007)

a. Inspection Scope

The inspectors assessed the adequacy of the Tennessee Valley Authority (TVA) and Bechtel program for identification, evaluation, and corrective action of conditions adverse to quality during the period since the previous problem identification and resolution inspection in April 2013. This was accomplished by reviewing selected PERs, verifying corrective actions were implemented and attending meetings where PERs were screened for significance to determine whether the licensee was identifying, accurately characterizing, and entering problems into the Corrective Action Program (CAP) at an appropriate threshold.

The inspectors reviewed a sample of PERs and Service Requests (SRs) selected from the applicants CAP for Watts Bar Unit 2. The sample included problems addressed by a diverse selection of plant departments and problems classified under all of the significance levels. The sample also covered a diverse selection of sources, including problems identified in audits and assessments, nonconforming results from inspections and tests, findings from NRC inspections, concerns from anonymous sources, and concerns identified as adverse trends. Most PERs were reviewed after corrective actions had been implemented; however, some were reviewed after the corrective action plan was developed but prior to implementation.

The inspectors also reviewed the applicants alternate issue tracking systems that address issues that were not classified as conditions adverse to quality. This review targeted verification of appropriate characterization and closure of issues managed outside the corrective action program. The alternative issue tracking systems that were sampled included Test Deficiency Notices (TDNs) and Quality Control (QC) Rejects.

These systems were defined as corrective Work Processes approved to track/implement correction, according to TVAs CAP procedure (NC-PP-3, Revision 15).

The inspectors reviewed applicable portions of TVAs and Bechtels Quality Assurance Program (QAP) implementing procedures in order to ensure that commitments for the identification, evaluation, and resolution of conditions adverse to quality had been adequately addressed. The inspectors review evaluated the applicants consideration for extent of condition, generic implications, common cause and previous occurrences (trending), including the identification of root and contributing causes along with actions to prevent recurrence for significant conditions adverse to quality.

The inspectors reviewed TVAs and Bechtels respective programs for resolving employee concerns. The inspectors interviewed TVA and the major contractors (Bechtel) employee concern representatives, reviewed a sample of PERs referred to employee concerns and PERs initiated as a result of employee concerns. The inspectors also reviewed several anonymous PERs to determine if they had been adequately captured and addressed. The inspectors reviewed and evaluated the adequacy of the programs, which provide employees with an alternate method to identify quality or safety-related concerns. The inspectors also reviewed surveys and assessments of the employee concerns programs.

The inspectors reviewed a sample of the applicants management and quality assessments, audits, and trend reports to verify adverse results were properly evaluated and dispositioned within the corrective action program. The inspectors reviewed the revision history for corrective action program implementing procedures and assessed the integration of industry operating experience into the corrective action process. Direct observations by inspectors included meetings of the Project Review Committee (PRC)and the Construction Completion Management Review Committee (CCMRC) as they screened newly reported problems and reviewed dispositions for selected issues.

Specific PERs and other documents reviewed are listed in the attachment.

b. Observations and Findings

No findings were identified.

The inspectors made the following observations as a result of their inspections:

(1) Effectiveness of Identifying, Evaluating, and Correcting Problems

Identifying Problems

The inspectors determined that, for the most part, the applicant was effective in identifying problems and entering them into the CAP. PERs normally provided complete and accurate characterization of the subject issues. Employees were encouraged by management to initiate PERs.

Evaluating Problems

The inspectors attended several meetings throughout the week, including the PRC and the CCMRC. It was determined that the applicant had adequately prioritized issues entered into the CAP consistent with established procedures. SRs that were being initiated and discussed during the meetings were being appropriately dispositioned. The inspectors determined that the threshold of closing items as SRs, closing items to a work order (WO), and creating a PER when necessary was adequate.

Correcting Problems

Based on a review of numerous PER corrective actions and their implementation, the team found, for the most part, that the applicants corrective actions developed and implemented for problems were commensurate with the safety significance of the issues.

(2) Use of Operating Experience

The inspectors determined that the applicants measures used to identify, evaluate and incorporate applicable industry and operating experience (I&OE) information into the corrective action program contained processes for including vendor recommendations and internally generated lessons learned. The I&OE information was collected, evaluated, and communicated to the affected internal stakeholders as specified in TVA and Bechtel procedures. The inspectors determined that appropriate corrective actions were developed and taken for the sample of I&OE problem evaluation reports reviewed for the Watts Bar Unit 2 Construction Completion Project.

(3) Safety Conscious Work Environment (SCWE)

The inspectors reviewed several anonymous PERs and PERs that either referred to the employee concerns program (ECP) or PERs generated as a result of employee concerns. Employees interviewed expressed knowledge of the employee concerns program and the ability to raise safety related concerns through various available means. The inspectors also interviewed senior employee concerns coordinators from both TVA and Bechtel. The inspectors determined that TVAs and Bechtels employee concern programs were adequate. The senior employee concerns coordinators expressed knowledge of the ECP and the ability to raise safety related concerns through various available means. The inspectors noted that the ECP staff provide several training sessions, they provide ECP information in newsletters, and they also walk around the site frequently, talk daily to staff, and attend several meetings to ensure that staff are aware of the ECP and know how to raise concerns if necessary. Also, there appeared to be strong management support for both the Bechtel and TVA ECP.

(4) Corrective Action Program Performance Insights

The sample of audits, assessments, and surveillances reviewed by the inspectors confirmed that management and quality personnel actively conducted observations and effectiveness reviews of the corrective action program. These program assessments concluded that overall, the corrective action program was effectively implemented. The applicant continues to track and trend issues, run summary reports on the trend data, and present results to management in several meetings, such as the site status meeting, CCMRC, etc.

(5) Corrective Action Program Effectiveness

As discussed above, in general, the applicants CAP was effective and adequate. The inspectors determined that the applicant has maintained implementation of the CAP at an effective level since the last NRC PI&R inspection (April 2013).

c. Conclusions

As documented above, the inspectors determined that implementation of the CAP for the Watts Bar Unit 2 construction completion project was generally adequate. The threshold for initiating PERs was appropriate, PERs were categorized in accordance with their significance, and problem evaluations were effective in identifying appropriate corrective actions.

In regards to maintaining a Safety Conscious Work Environment, the inspectors determined that TVA and Bechtel had established an acceptable program and environment for allowing employees to identify quality or safety-related concerns.

V.

Management Meetings

X.1

Exit Meeting Summary

On April 25, 2014, the inspectors presented the inspection results to you and other members of your staff. Proprietary information reviewed during the inspection was returned and no proprietary information was included in this inspection report.

SUPPLEMENTAL INFORMATION

Partial List of Persons Contacted

Applicant personnel

D. Charlton, TVA - Licensing
T. Cheek, TVA - CAP Manager
M. Cooper, TVA - CAP Oversight
B. Gillham, TVA - Licensing
B. Heinmiller, Bechtel - CAP Manager
Y. Hink, Bechtel - Employee Concerns
R. Kirckpatrick, TVA - Engineering
T. Niessen, TVA Audits & Assessment Manager
J. ODell, TVA - Regulatory Compliance
L. Reaves, TVA - Employee Concerns
K. Rose, Bechtel - CAP Coordinator
G. Scott, TVA - Licensing
D. Voeller, TVA - Construction Manager
N. Welch, TVA - Preoperational Startup Manager

Inspection Procedure Used

IP 35007

Quality Assurance Program Implementation during Construction

List of Items Opened, Closed, and Discussed

Opened

None

Opened and Closed

None

Discussed

None

List of Documents Reviewed

Problem Evaluation Reports

2178

Trend in Red-Line Process Issues

394793

Ineffective Preventive Actions Associated with PER 262178

581841

ASME Non-conformance

615657

Improvements Needed to Prevent Recurrence of Missed QC Holdpoints

706129

Potential problem with Westinghouse ARD relays for DC application

708450

NRC Id'd: Hardware Non-Conformance for HVAC Support in Closed WO 709036

Anonymous PER: Hostile Work Environment

709637

Multiplication Error in Rosemount 1152 Calculation

713135

ASME Hardware Non-Conformance DRAVO Spool S/N 11450 Historic Issue

713742

PER closure - QA Assessment NC-WB-13-006

715564

NRC Id-d: Upper Lateral Support Material Not Tested In Accordance with

Requirements

24028

WO 110932752 does not provide adequate precautions for work on ABSCE support

25478

ASME III Hardware Non-Conformance.Sys 030/067 Indication On Piping For

WBN-2-Ccu-030-0078-B

735081

Hardware Non-Conformance: QA3 Mat'l Used In QA1 Application. Sys 3, 61, 62, 63,

68, 70, 72

738567

Missing cross reference for PER to WO 738580

Work not completed to address non-conforming condition

739613

Evaluate Westinghouse TB-13-1 applicability to WBN2.

741744

Historical: Wood insulation discovered in ice condenser personnel access door

2527

CCE, SYS WBN063, WBN-2-3VC-293-6044-B, Conduit exceeds 360° bends with

cable pulled in

2574

Unit 2 construction radiography. Weld 2-062B-D139-27 C1R0; metallic debris in pipe

743615

Adverse Trend for By-passed ANI/QC Holdpoints, Witness points, reviews, and

notifications

745899

Supplier Quality Rep, personnel qualification records are not in EDMS

748557

Common Q Panels may not have properly adjusted retaining angle brackets for

seismic event

750214

Anonymous PER: Bechtel Supervisor rushing craft to the field w/o proper paperwork

753260

ASME related: Failure to follow procedure MGT-0003

754455

A Dye Penetrant Exam Of Weld# 2-063b-T071-28-C0r0, Revealed A 3-1/2" Linear

Indication In The Pipe

754469

ASME Related, Errors in PCI Documents (RTD Bypass) Found During Final Review

756990

Potentially Reportable Hardware Non-Conformance: 10 CFR Part 21 notification

763291

Pressurizer PORV Cv Design Change

766429

Errors in WBNTSR008 calculation

766488

Anonymous PER: Issues with FCR approval process

777477

Personal documenting approval of ASME Section III Design Specification not

adequately qualified

781458

QA identified Adverse Trend in CAP Action Closure Quality

788677

Anonymous PER: Work orders have recurring problems

790185

Unauthorized Rework on Flex Conduit 800044

790717

Review of WO#110990376 R1 CCE, SY

S. WBN074, and WBN063 associated

commodities

790722

Incorrect dimensions not identified on FCR 61876 AA-02

790730

ASME: Missing dates for approval/concurrence reviews for Supplier Quality

Procedure and Manual

791834

FCR written to document As-built condition of installation does not match layout

piping DRA

793461

Work Order Signatures

794620

ASME WO 111059418 was closed without obtaining N-5 and ANI final review as

required by N1206

794668

Vendor Heat Loss Calculation for Metal Reflective Insulation Does Not Match Design

Drawings

800044

NRC Identified, Potential Over Torque of Wrapper Plug Assembly

800570

Unit 2, 2-FCV-070-0087 MOV actuator mounting hardware is not correct 802311

ASME WO 115220992 WBN-2-CKV-062-0532-B SENSITIZATION

804263

ASME System WBN068 Issues found with Archived PER 215474 & BIT 1405

807454

Instrumentation tubing sulfur content outside acceptable values for orbital welding

808623

PRZR instrument nozzle couplings removed

819918

Anonymous PER: Work Orders not Being Worked per Procedures

2473

Cable 2PV6750 in Bend Radius Violation (SYS WBN098)

2928

System WBN067 TIC's may not maintain position retention

834004

Hardware Non-conformance: 3/4" rebar was cut without authorization

838631

ECP Referral: Potential damaged rebar and tube bending tool causing damage to

3/4" SS tubing

2892

Insufficient Clearance Between Valve WBN-2-CKV-063-0634 and Crane Wall

2964

SU Trend PER due to HU incidents at undesirable level

844207

SUT SYS WBN027 TDN 13-446 Time Delay Relays did not meet acceptance Criteria

844218

NRC Identified: Unit 2 Rack 2 Narrow Range RTD WO 113471100 PMT Data

844222

TDN Trending and Processing Errors

844234

NRC Identified - Valve data sheets reference incorrect material specification

845228

System WBN063 Potential Proximity Interactions

850485

Pipefitter performed unauthorized work

851810

During disassembly of the 2A Safety Injection Pump, multiple deficiencies were

identified

857648

Anonymous PER: Craft Being Pushed to Work Fast in an Unsafe Manner

857667

ASME Section III Components - Trend PER - assembly quality issues with OEM

Flowserve

861461

PER 469477 and PER 708506 have been closed without all actions being

completed/addressed as required

863840

SUTR SYS WBN062 WBN-2-GR-062-0108-A

875435

Administrative Closure Issues Found during and Engineering Review of Closed

PERs

2509

Incorrect wire installed on the output side of Temperature Modulators

875435

Administrative Closure Issues Found during an Engineering Review of Closed PERs

876414

Missing 18 inch mirror insulation at Acc room #3,el. 702' Az 180, SIS piping

877650

CCM SYS WBN040 UNID-2-PIPE-040-G. Nail identified inside RCP 4 oil drain line

on EL. 716

877665

PI&R NRC ID'd: ASME Code III Hardware SRs closed to work performed, rather

than going to a PER

Service Requests

695055

Existing Root Valve 2-RTV-062-0442A is not operating smoothly

24339

Loose bolting on 2-RFV-067-0573B-B

24351

Loose bolting on 2-RFV-067-1033A-A, 1029B-b and 2-FE-067-0183

24525

SR closed to WO for ASME item without creating a PER

2302

Hardware Non-conformance: QA3 Mat'l used in QA1 Application, SYS 3, 61, 62, 63,

68, 70, 72

739452

Commodity Clearance Violation on HVAC Support 75-4517

739531

ASME Hardware Nonconformance Inadequate Socket Depth of Valves 2-DRV-068-

0557 and -0558

754881

MAI-5.1B requirements were not completed, System WBN293

780734

QA identified Adverse Trend in CAP Action Closure Quality

787376

Loose Bolting on Relief Valve in Unit 2

2916

Solenoid Valve top cover bent

807559

Historical Issue: Broken Embedded Ground Cable

836724

ASME Hardware Nonconformance - System 6.1 Indications Violated Min Wall Repair

IAW Bechtel SPM

855583

ASME Section III Components - Trend PER - assembly quality issues with OEM

Flowserve

863108

SUTR SYS WBN062 WBN-2-GR-062-0108-A

875013

Administrative Closure Issues Found during and Engineering Review of Closed

PERs

875329

CCM SYS WBN040 UNID-2-PIPE-040-G. Nail identified inside RCP 4 oil drain line

on EL. 716

876118

Missing 18 inch mirror insulation at Acc room #3,el. 702' Az 180, SIS piping

876378

PI&R NRC ID'd: ASME Code III Hardware SRs closed to work performed, rather

than going to a PER

Test Deficiency Notices13-217

2-HS-67-111C hand switch does not operate valve, no continuity in switch contact

circuit

13-244

Torque switch operation is suspect

13-280

Max seating/unseating est motor torques exceeds limit on design rwg

13-281

Running average est motor torques exceeds limit on design rwg

13-338

Fuses are blowing after long delay

13-361

No seating torque on MOVATS; suspect not tightly closed

13-390

MEL data is not filled out correctly

13-486

High running load during MOVATS test

13-505

Packing/running load exceeded

13-515

High running load during MOVATS test

13-525

Diode in JB 1910 is installed in the reverse direction

13-526

Diode in JB 1910 is installed in the reverse direction

14-046

High packing/running load

14-058

Packing/running load exceeded

14-108

Wiring issue. DRA does not match Cat 1 drawing

14-204

Unclear design output for valve stroke time requirements

Procedures and Programs

25402-MGT-000, Corrective Action Program, Rev. 16

25402-MGT-0004, Incident Investigation and Root Cause Analysis, Rev. 4

25402-000-GPP-0000-N3702, Arc Strike Removal / Base Metal Repair of Piping / Components

and Structural / Miscellaneous Steel, Rev. 2

25402-00-GPP-0000-N1206, "Work Order Processing," Rev. 18

NC-PP-3, Watts Bar Unit 2 Corrective Action Program, Rev. 15

NC-PP-8, Watts Bar Unit 2 Operating Experience / Construction Experience Plan, Rev. 2

NC-PP-6, Completion of TVA NC Partial ASME Section III Division 1 N-5 Data Reports,

Rev. 13

NPG-SPP-06.4, Measuring and Test Equipment, Rev. 2

Audit Reports

Audit Report No. NC1302, Corrective Action Program, dated 6/26/13

Bechtel Audit No. 25402-WBN-AR13-0002, Bechtel Quality Assurance Manuals, Rev. 0

Quality Assurance Assessment Report NC-WB-13-006, Problem Evaluation Report Closures,

dated 4/18/13

Miscellaneous

2013 Assessment of WB2 Safety Conscious Work Environment and Safety Culture

Bechtel Annual SCWE Pulsing Survey; 2012 and 2013 Results Comparison

Bechtel CAP Status Report, dated February 2014

Bechtel Employee Concerns Cases Associated with PERs; 04/01/2013 through 04/23/2014

CAP Trend Report; March 2014

Test Deficiency Notice Trending; 03/19/2014 through 04/17/2014

Watts Bar Nuclear Plant U1/U2 Corrective Action Program Transition Strategy Document

WBC ECP Pulsing Results; Completed 10/23/2013

WBC ECP Pulsing Results; Completed 03/27/2014

WBN U2 CAP Metrics Report, dated February 2014

WBN U2 CAP Self-Assessment WBN2-CAP-14-1, dated 3/25/14

Drawing

2-45B2768-11E, Rev. 7

2-47A8910-63-01, Rev. 2

Calculation

MDQ0020632008-0229, Rev. 003

Field Change Requests

FCR 60603-A, DRA No. 5331-168, -190, -408, and -409, Rev. 0

FCR 59905-A, AA-07, dated 8/1/12

Work Orders

WO 114633238, CCM SYS 067 WBN-2-RFV-067-1033A-A ASME Class 3

WO 115149219, CCM EDCR2 53580 SYS 063 PER 760933 2-RFV-063-0627-B PER 760933

FCR 61757-A AA-09

List of Acronyms

ADAMS

Agencywide Document Access Management System

CAP

Corrective Action Program

CCMRC

Construction Completion Management Review Committee

CFR

Code of Federal Regulations

ECP

Employee Concerns Program

I&OE

Industry and Operating Experience

IP

Inspection Procedure (NRC)

NRC

Nuclear Regulatory Commission

PARS

Publicly Available Records

PER

Problem Evaluation Report

PI&R

Problem Identification and Resolution

PRC

Project Review Committee

QA

Quality Assurance

QAP

Quality Assurance Program

QC

Quality Control

SCWE

Safety Conscious Work Environment

SR

Service Request

TDN

Test Deficiency Notice

TVA

Tennessee Valley Authority

WBN

Watts Bar Nuclear Plant

WO

Work Order

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