Nuclear Maintenance Management Program TFC-PLN-29, …_Nuclear... · Nuclear Maintenance Management Program Manual Document Page Issue Date Management Plan TFC-PLN-29, REV C-15 2

Nuclear Maintenance Management

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TFC-PLN-29, REV C-15

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Ownership matrix

USQ # 17-1269-D

TABLE OF CONTENTS

1.0 PURPOSE AND SCOPE ................................................................................................................ 2 2.0 METHOD OF REVIEW ................................................................................................................. 2 3.0 PROGRAM ELEMENTS AS APPLIED BY WRPS ..................................................................... 3

3.1 Maintenance Organization and Administration .................................................................. 3 3.2 Master Equipment List ........................................................................................................ 3 3.3 Planning, Scheduling, and Coordination of Maintenance ................................................... 3 3.4 Types of Maintenance ......................................................................................................... 5 3.5 Maintenance Procedures ..................................................................................................... 5 3.6 Training and Qualification .................................................................................................. 6 3.7 Configuration Management ................................................................................................ 7 3.8 Procurement ........................................................................................................................ 8 3.9 Maintenance Tool and Equipment Control ......................................................................... 9 3.10 Suspect and Counterfeit Items ............................................................................................ 9 3.11 Maintenance History ......................................................................................................... 10 3.12 Aging Degradation and Technical Obsolescence ............................................................. 10 3.13 Seasonal Facility Preservation .......................................................................................... 11 3.14 Performance Measures ...................................................................................................... 11 3.15 Facility Condition Inspection ............................................................................................ 11 3.16 Post Maintenance Testing ................................................................................................. 13 3.17 Integration with Regulations and DOE Orders and Manuals ........................................... 13

4.0 SOURCES ..................................................................................................................................... 14 4.1 Requirements .................................................................................................................... 14 4.2 References ......................................................................................................................... 14

TABLE OF TABLES

Table 1. TOC Program Plans Applicable to the NMMP. .......................................................................... 18

TABLE OF ATTACHMENTS

ATTACHMENT A - MAINTENANCE PROGRAM IMPLEMENTING PLANS/PROCEDURES AND

PROCESSES .............................................................................................................................. 20

http://toc.wrps.rl.gov/rapidweb/PRO/index.cfm?pageNum=232


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1.0 PURPOSE AND SCOPE (4.1.1, 4.1.2)

The Nuclear Maintenance Management Plan (NMMP) is established to comply with the

U.S. Department of Energy (DOE) O 433.1B, “Maintenance Management Program for DOE

Nuclear Facilities.” The NMMP describes the safety management program for maintenance and

the reliable performance of structures, systems and components (SSCs) that are part of the safety

basis required by 10 CFR 830.202 at hazard category 1, 2, and 3 Department of Energy (DOE)

nuclear facilities. The NMMP is not applicable to non-nuclear facilities (e.g., Cold Test Facility,

mobile offices, 2750E, 2704HV, and other office buildings, including those south of the Wye

Barricade).

The Nuclear Maintenance Management Plan (NMMP) provides reference to implementing

procedures/programs for each area discussed, and documents reasons for deviating from the

guidance where appropriate. Although the NMMP does not apply to non-nuclear facilities

(e.g., Cold Test Facility, mobile offices, 2750E, 2704HV, and other office buildings, including

those south of the Wye Barricade), the NMMP discusses processes such as work release that may

have application to a non-nuclear facility. Attachment A directs the reader to the appropriate

implementing procedure for each program element identified in the NMMP.

Washington River Protection Solutions, LLC (WRPS) uses a graded approach to implementing

the specific requirements of DOE O 433.1B.

Graded approach, as defined in 10 Code of Federal Regulation (CFR) Part 830, “Nuclear Safety

Management,” means the process of ensuring that the level of analysis, documentation, and

actions used to comply with a requirement in this part are commensurate with:

The safety, safeguards, and security function provided;

The magnitude of any hazard involved;

The life cycle stage of a facility;

The programmatic mission of a facility;

The particular characteristics of a facility;

The relative importance to radiological and non-radiological hazards; and

Any other relevant factor.

The NMMP is required to be submitted to the Department of Energy-Office of River Protection

(DOE-ORP) for approval every three years. Changes to the NMMP are required to be evaluated

in accordance with TFC-ENG-SB-C-03. Changes to implementing documents discussed in the

NMMP do not require DOE-ORP approval but need to be evaluated to ensure the change does not

affect the NMMP.

2.0 METHOD OF REVIEW

This document has been prepared by reviewing the 17 major elements found in DOE O 433.1B,

Attachment 2, reviewing guidance provided in the Nuclear Facility Maintenance Management

Program Guide DOE G 433-1-1A Chg 1 and evaluating the direction provided in the

implementing documents discussed in the NMMP to ensure adequate direction is provided to

demonstrate compliance with the order.

http://idmsweb/idms/livelink.exe/Open/3530338


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3.0 PROGRAM ELEMENTS AS APPLIED BY WRPS

3.1 Maintenance Organization and Administration

TFC-CHARTER-01 defines the organizational alignments and summary level roles and

responsibilities for the implementation of the Tank Operations Contractor (TOC) mission. The

Maintenance Organization was established as a separate group in 2015. The organizational

structure has a Maintenance Manager with four groups reporting to this position: Craft Support,

Work Control, Programs, and Contractor Assurance.

Administrative procedures/processes provide direction for the development of technical

procedures and work orders that incorporate management policies and assign responsibility for

implementation.

Administrative procedures are used to implement maintenance program requirements (e.g., lock

and tag, scaffolding use, control of Measuring and Test Equipment, use of qualified spare parts,

inspection criteria). Technical and administrative controls are specified in work instructions

developed in accordance with TFC-OPS-MAINT-C-01. The maintenance function involves

integrating activities and requirements of multiple organizations (e.g., operations, health physics,

engineering, safety) to plan, review, and execute work. The work force is involved at all levels

and in all phases of the work (planning and execution), allowing for feedback to improve safety,

reliability, quality and productivity.

TOC management uses performance indicators, system health reports, operating data, self-

assessments, and management observations to monitor various aspects of the maintenance

program.

3.2 Master Equipment List

The Master Equipment List (MEL) for the TOC is contained in SmartPlant®1 Foundation (SPF)

per TFC-ENG-FACUP-C-23. Equipment Identification Numbers (EIN) are assigned for

components of safety systems, equipment that is vital to continued operation and mission

accomplishment, equipment that is required to satisfy environment regulations, and any

equipment that requires periodic maintenance unless the periodic maintenance is managed by

contract and the maintenance is scheduled and tracked using another system (e.g., fire systems,

radiological control instrumentation, and 222-S Laboratory equipment). Equipment listed in SPF

with an EIN comprises the MEL. TFC-ENG-FACSUP-C-23 details the process for

developing, implementing, managing, and maintaining the MEL.

TFC-OPS-MAINT-C-12 provides direction for maintenance personnel in the use of the Work

Management System (WMS) and SPF to identify and apply appropriate controls to maintenance.

3.3 Planning, Scheduling, and Coordination of Maintenance

Production Operations and Single Shell Tank (SST) Retrievals ensure maintenance actions are

scheduled and closely monitored to ensure maximum equipment operability of:

SSCs

Environmental and regulatory equipment

1 SmartPlant® is a registered trademark of Intergraph, Corporation of Madison, Alabama.




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Equipment necessary to support operational needs.

Production Operations, SST Retrievals, and various project managers participate in integrated

schedule meetings to establish work priorities and assign resources to support operational

evolutions, construction, and maintenance activities. Work activities are coordinated by a

detailed review of the Plan of the Week, and daily by reviewing the work plan of the day (work

release sheet). Maintenance, Operations, and supporting personnel attend the Plan of the Week

and Plan of the Day meetings to discuss resource needs and resolve any potential work conflicts.

Highest priority is assigned to correct imminent safety hazards, restore inoperable safety SSCs,

and restoration of environmental/regulatory equipment.

TFC-ENG-FACSUP-P-01 describes the system engineer program and establishes the

responsibilities of the cognizant system engineer (CSE) in accordance with DOE O 420.1C. The

CSE plays a role in the planning and prioritization of maintenance activities, in accordance with

DOE O 420.1C. In particular, the CSEs:

Ensure that system configuration is managed effectively

Remain apprised of the operational status and ongoing modification activities

Assist in review of key system parameters and evaluating system performance

Initiate actions to correct problems

Remain cognizant of system-specific maintenance and operations history, industry

operating experience, as well as manufacturer and vendor recommendations, and any

product warnings regarding safety SSCs

Identify trends from operations and maintenance associated with the safety SSCs

Provide assistance in determining operability, correcting out-of-specification conditions,

and evaluating questionable data

Provide or supporting analysis when an SSC is suspected of inoperability or degradation

Review and concur with design changes

Review, and provide input into the development of operating, maintenance, and test

procedures.

TFC-OPS-MAINT-C-01 addresses work origination, screening, work package planning,

pre-release review, work authorization/release, work instructions, and post maintenance testing.

All work in the nuclear facilities at Tank Farms and 222-S Laboratory is reviewed to ensure the

facility conditions support conducting the work safely, and that the work instructions include

appropriate steps to comply with safety basis and environmental/regulatory requirements.

TFC-OPS-MAINT-C-12 discusses management of the preventive maintenance (PM) program

and TFC-OPS-OPER-C-65 outlines the Rolling Schedule process.





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3.4 Types of Maintenance

Preventive maintenance requirements (e.g., functional checks, calibrations, mechanical

inspection, cleaning) are tracked in the Computerized Maintenance Management Software

(CMMS). The goal of the PM program is to maximize equipment availability by eliminating

hidden faults before equipment is disabled. The maintenance requirements and the periodicity is

established by engineering taking into consideration the operational history of the equipment,

input from maintenance craft, technical safety requirements, vendor suggested maintenance, and

codes and standards (e.g., National Electric Code, Washington Administrative Code,

environmental regulations). Equipment not routinely used is calibrated or otherwise maintained

before use (if required). When it is determined that a PM activity is no longer required (e.g.,

equipment no longer in use), the PM activity is discontinued or inactivated in CMMS.

RPP-7574, “Double Shell Tank Integrity Program Plan,” is a comprehensive program to ensure

the continued viability of the Double-Shell Tanks (DSTs) to support the Hanford mission. The

program utilizes predictive maintenance technologies (e.g., video inspections and ultrasonic

testing) to inspect DSTs and 242-A Evaporator components. Additionally the DST Integrity

Program performs integrity testing and certification of pipelines, visual inspections of valve pits,

and hydrostatic testing of evaporator components.

TFC-ENG-FACSUP-C-23 is the administrative procedure for identifying equipment requirements

and entering them into CMMS. TFC-OPS-MAINT-C-12 is the process used to administer the

preventive maintenance program.

Work orders to complete PM activities provide work instructions with sufficient detail to identify

and mitigate potential hazards, complete the maintenance requirement, and document the results.

When out-of-tolerance/deficient conditions or unexpected results are obtained, and authorized

work steps do not restore the system/component to in-specification operating conditions, the

system/component engineer is notified. If the identified problem is not corrected, the equipment

will be taken out of service until repairs are made using a corrective maintenance work order, or

the equipment use is restricted as determined by engineering.

Corrective maintenance is prioritized by taking into account personnel safety, technical safety

requirements, environmental requirements and mission needs.

3.5 Maintenance Procedures

There are two primary procedure types used:

Operating procedures developed in accordance with TFC-OPS-OPER-C-13 provide

technical direction for manipulating systems/components and operating equipment

Work instructions contained in work packages developed using TFC-OPS-MAINT-C-01

to provide specific direction for performing maintenance work on systems/components.

TFC-OPS-OPER-C-13 establishes the minimum requirements for the TOC technical procedures.

Technical procedures are used for guidance and control of Tank Farm operations, maintenance,

surveillance, radiological control, and emergency response.

TFC-OPS-MAINT-C-01 defines work management from initiation of a work request through

work order closeout, and applies to all TOC personnel who schedule, plan, approve, release, and

perform operations acceptance or post-review using work orders.








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Multiple Safety Management Programs (See Table 1) and their associated implementing

documents are involved with planning work and to incorporate environmental, nuclear safety

basis, quality assurance and industrial safety requirements. Proper integration of requirements is

essential for implementing TFC-PLN-01, “Integrated Environment, Safety, and Health

Management System Plan” as discussed in RPP-MP-003, “Integrated Environment Safety and

Health Management System Description for the TOC.” Procedures involved in planning work

include but are not limited to:

DOE-0359, “Hanford Site Electrical Safety Program”

TFC-OPS-MAINT-C-01, “Tank Operations Contractor Work Control”

TFC-ESHQ-S_SAF-C-02, “Job Hazard Analysis”

TFC-ENG-DESIGN-C-06, “Engineering Change Control”

TFC-ENG-STD-08, “Post Maintenance Testing”

TFC-ESHQ-RP_ADM-C-11, “Joint Review Group”

TFC-ESHQ-RP_RWP-C-03, “ALARA Work Planning”

TFC-ESHQ-RP_RWP-C-04, “Radiological Work Permits.”

3.6 Training and Qualification

Maintenance is performed by personnel who have completed the training requirements

established by management in accordance with DOE O 426.2, “Personnel Selection, Training,

Qualification, and Certification Requirements for DOE Nuclear Facilities.”

TFC-BSM-TQ-STD-10 describes the qualification process and training program

applicable to Instrument Specialists, Electricians, Millwrights and Pipefitters.

TFC-BSM-TQ-STD-03 describes the qualification and training program for personnel

who supervise maintenance activities and operations work.

TFC-BSM-TQ-STD-01 defines the requirements for qualifying personnel in various

technical technician and support staff positions.

Maintenance personnel are informed of changes to plant policies, procedures, systems, and

equipment by ensuring only the most recent approved procedures are used when performing an

activity; by pre-job briefings; by periodic briefings by supervisors/managers (e.g., tailgates); and,

when appropriate, by familiarization training.

Workers who can access nuclear facilities are required to meet specific requirements for

radiological workers. This training process ensures that personnel demonstrate their knowledge

of the proper use of personal protective equipment (PPE) worn to prevent personnel

contamination. This training also ensures that personnel have a basic understanding of actions to

minimize radiation exposure, and action to take in the event of degrading radiological conditions.

In addition, personnel who may be required to wear respiratory equipment receive specialized

training on each type of respirator they are authorized to use. Other training, such as the

Hazardous Waste Course, provides workers with knowledge and use of PPE for various

hazardous situations. Some craft have specialized training and PPE requirements applicable to

the hazards associated with their work.












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TFC-PLN-47 discusses that the TOC has established a worker safety and health training and

information program within a training and qualification plan. Management, with input from

health and safety professionals, uses standard training profiles, coupled with the employee job

task analyses in determining: 1) training requirements based on hazards in the workplace,

2) tasks the employees will perform, 3) requirements based on worker classification (e.g., field

work supervisors, radiological worker), and 4) technical staff position qualifications (e.g., system

engineer, quality assurance engineer, operations engineer). The training organization and

management, use a web-based electronic integrated training matrix to track and ensure that all

workers exposed or potentially exposed to hazards are provided with the training and information

on that hazard in order to perform their duties in a safe and healthful manner. The program

provides training and information for new workers, before or at the time of initial assignment to a

job involving exposure to a hazard. Periodic training is provided as often as necessary to ensure

that workers are adequately trained and informed. Additional training is provided when safety

and health information or a change in workplace conditions indicates that a new or increased

hazard exists. The TOC has established a technical staff qualification plan to ensure training and

information is provided to employees who have worker safety and health program responsibilities

that is necessary for them to carry out those responsibilities.

The TOC utilizes other Hanford Prime Contractors for resources to perform work that is within

the defined scope of their respective contracts with the DOE. Examples of work performed by

other Hanford contractors include Fire System Maintenance preventive and corrective work,

Heating/Ventilation/Air Conditioning preventive and corrective work and road

maintenance/repair. The work is performed and managed through Interface Agreements, which

are developed per TFC-BSM-CP_CPR-C-17. The resources from other Hanford contractors must

meet the training requirements to perform work within the TOC.

3.7 Configuration Management

TFC-PLN-23 documents the TOC Configuration Management (CM) program that establishes

consistency among design requirements, physical configuration, and documentation (including

analysis, drawings, and procedures) for the activity, and maintains this consistency throughout the

life of the facility or activity, particularly as changes are being made.

Fulfilling the configuration management objective is accomplished through the key configuration

management elements: design requirements, work control, change control, documentation

control and assessments. The key configuration management elements are followed by all

personnel, using an integrated process when performing activities that affect SSCs. The CM

process includes policies, management plans, work practices, and procedures that are used by

WRPS and its subcontractors.

The TOC CM program is a non-credited Safety Management Program (SMP) briefly described in

TOC Safety Basis documents (RPP-13033, “Tank Farm Documented Safety Analysis”; HNF-

12125, “222-S Laboratory Documented Safety Analysis”; and HNF-14755, “242-A Evaporator

Documented Safety Analysis”). This plan is required by DOE-STD-1073, “Configuration

Management.” This standard is invoked by TFC-POL-07. The CM program is compliant with

the CM requirements of U.S. Department of Energy (DOE) Orders DOE O 420.1C, “Facility

Safety”; DOE O 413.3, “Program and Project Management for the Acquisition of Capital

Assets”; DOE O 433.1B, “Maintenance Management Program for Nuclear Facilities”; DOE O

422.1, “Conduct of Operations”; and ASME/NQA-1, “Quality Assurance Requirements for

Nuclear Facility Applications.”




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3.8 Procurement

TFC-ENG-DESIGN-C-34 defines the requirements associated with the preparation, review,

approval, release, and revision of engineering/technical requirements for such items as catalog

items, developmental technology, engineered equipment, design/build procurements and

construction. It provides for simpler, alternate process for conveying engineering/technical

requirements during procurement, when the complexity of procurement does not require a

standalone specification.

TFC-ENG-DESIGN-C-15 establishes the dedication process, dedication requirements, and

related responsibilities for the use of commercial grade items as safety significant components, in

safety significant applications for Hanford TOC managed nuclear facilities. These activities are

performed to ensure that the safety functions of safety significant items are preserved (i.e., the

commercial grade item is suitable for use in its intended application and that the item will

perform its safety function) and to protect the design baseline from being inadvertently changed.

TFC-BSM-CP_CPR-C-05 defines the process for procurement planning, execution, and closeout

of subcontracted tank farm services and construction work scope.

TFC-BSM-CP_CPR-C-06 defines the process for procuring quality level materials or items

utilizing a Bill of Material (BOM) or a Material Requisition (MR). This process is used for the

procurement/acquisition of engineered equipment, materials for construction activities, corrective

and PM materials, fabricated parts or components, permanent material installations, and direct

materials (future field installations, tool crib supplies/stock, hand tools, shop stock, operations

supplies, and maintenance supplies) for WRPS.

TFC-BSM-CP_CPR-C-19 provides the process for the identification, review and approval,

procurement, and inventory management of spare parts, and spare equipment. Spare parts are

established in inventory, as appropriate, to maintain continuity of facility operations and to reduce

system and facility downtime through availability of the identified parts.

TFC-BSM-CP_CPR-C-18 outlines the processes for:

Receiving, staging, issuance, storage, handling, and return to inventory materials,

equipment, supplies, and consumables (including using the Field Bill Of Material and

Preliminary Engineering Change Notice [ECN] process to complete current field

conditions work)

Receipt, handling, storage and issuance of construction material for completed, canceled

or suspended projects

Tool Crib operation and requirements related to control of suspect/counterfeit items

(S/CIs)

Controlling convenience storage material inventory

Removal and reuse of existing parts and assemblies

Disposal of government owned equipment and surplus property.








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3.9 Maintenance Tool and Equipment Control

TFC-OPS-MAINT-C-03 describes the requirements for maintaining, using, issuing, storing, and

controlling tools and equipment needed to support TOC maintenance activities.

Measuring and Test Equipment (M&TE) used to calibrate installed plant instrumentation or to

obtain data specified by Engineering is controlled in accordance with TFC-OPS-MAINT-C-07.

All M&TE used to support calibration, functional testing, and data collection is calibrated and

traceable to nationally recognized standards, and performed by a certified lab repair facility with

the specialized equipment and qualifications necessary to comply with quality assurance

requirements. In the event that a Notice of Discrepancy is received documenting a problem with

M&TE, an evaluation by Engineering is conducted to determine appropriate corrective action.

This action may require recalibration using a different piece of M&TE, or an engineering

evaluation explaining why recalibration is not necessary. The tool cribs maintain a list of M&TE.

M&TE used by the Industrial Hygienist and Radiological Controls is controlled as described

below:

TFC-PLN-64, “Industrial Hygiene Instrumentation Plan,” describes the Tank Operations

Contractor (TOC) industrial hygiene instrumentation program elements and

responsibilities for developing and implementing the program. The industrial hygiene

instrumentation program is designed to establish criteria to ensure a systematic and

methodical approach to instrument selection, use, control, calibration and maintenance.

TFC-ESHQ-RP_INS-P-05, “Radiation Protection Instrument Program,” describes the

radiation protection instrument program, defining the requirements and company-wide

practices for radiological control monitoring instrumentation and equipment.

3.10 Suspect and Counterfeit Items

TFC-ESHQ-Q_C-C-03 describes the process for the identification, prevention, evaluation,

notification, and disposition of suspect/counterfeit items (S/CIs) at WRPS. This procedure

applies to items that are:

In the procurement cycle

In receiving inspection

In inventory at warehouses and staging areas

Installed

In operation.





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3.11 Maintenance History

All work orders generated in CMMS are maintained electronically and are easily retrieved. This

includes corrective and preventative maintenance, and facility modifications. The work planner

can access this information during the work planning process. The work orders provide a

description of work performed; parts that were used, inspection results, test equipment used, and

retest data. This maintenance history can be reviewed and used to develop the Quarterly System

Health Reports. System Health Reports present the concise status of the assigned system during

the most recent quarter and limited data from the previous quarter in key performance areas for

comparison. The system health report provides a tool for the system engineer and the responsible

manager to identify trends in system performance and issues that require attention. The reports

also provide management the ability to recognize emerging problems in order to ensure system

engineers and site facilities are provided the support they need. Maintenance history is

considered when scheduling operations that require special equipment (e.g., waste transfers) and

when scheduling maintenance activities that require special considerations (e.g., electrical outage

during cold weather conditions).

3.12 Aging Degradation and Technical Obsolescence

WRPS applies a graded approach to inspections/evaluations for age degradation and technical

obsolescence, placing more emphasis on those SSCs that are part of the safety basis and therefore

required to protect the work force, the public, and/or the environment.

Periodic performance of Technical Safety Requirements (TSR) Surveillance Requirements (SR)

and Design Feature (DF) inspections, and/or integrity assessments are used demonstrate that

equipment is capable of performing its intended safety function. Satisfactory performance of the

required TSR SR and DF inspections demonstrates that the safety SSCs can perform their

intended safety function. However, these TSR required actions (SR and DF inspections) may

also reveal deteriorated safety SSCs including deterioration associated with aging. Technical

Safety Requirements for safety SSCs are performed in accordance with approved operating

procedures or preventative maintenance work packages. TFC-OPS-OPER-C-01 describes the

actions required to ensure compliance with the TSRs to ensure execution of the operating

procedures or PM work packages associated with the various safety SSCs. Maintaining

compliance with the TSRs ensures that safety SSCs are able to meet their intended safety function

and functional requirements.

In addition, WRPS reviews the 242-A Evaporator, DSTs, and ancillary equipment that are

expected to exceed their design life. Accordingly, the DST Integrity Project (DSTIP) was

developed to ensure that the systems can meet the mission goals. RPP-7574, “Double Shell Tank

Integrity Program Plan,” provides controls and inspections that ensure system integrity is

maintained throughout the mission, including the 242-A Evaporator. DST Integrity Project

activities include the following principal elements:

242-A Evaporator and DST integrity assessments (e.g., ultrasonic and video

examinations) and documentation of results for use in periodic re-inspections

DST waste chemistry sampling and adjustments for corrosion mitigation

DST waste chemistry corrosion optimization studies to quantify the best waste chemistry

parameters to minimize DST corrosion


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Development and installation of in-tank corrosion probes for DSTs with new or revised

corrosion control limits

DST structural analysis and studies for thermal, operating, and seismic loads

Periodic testing, evaluation, and certification of DST support equipment such as waste

transfer lines, valve pits, AZ-301, etc.

RPP-PLAN-45082, “Implementation Plan for the Single Shell Tank Integrity Project” provides

details of a project to ensure the integrity of the SSTs until the waste can be retrieved from the

tanks for treatment.

Safety SSCs are considered technically obsolete when those SSCs are no longer supported by the

manufacturer. Technical obsolescense of safety SSCs can be identified by activities, such as but

not limited to:

Manufacturer communication regarding their plan to discontinue support for specific

models,

Parts availability at time of purchase

Period review as described in RPP-PLAN-59958, Process & Control System Engineering

Software & Equipment Obsolescence Plan

Problem Evaluation Requests (PER) in accordance with TFC-ESHQ-Q-C-C-01

Replacements for obsolete safety SSCs is accomplished following the modification process

initiated by the Modification Traveler in accordance with procedure TFC-ENG-DESIGN-C-56.

3.13 Seasonal Facility Preservation

TFC-BSM-FPM_PR-C-13 provides seasonal facility preservation expectations, and defines the

responsibilities and requirements for implementation, surveillance, and securing from cold

weather and facility preservation during the winter months. TFC-ENG-STD-02 requires that the

design of safety SSCs includes methods to protect the SSCs from adverse weather conditions.

Engineering specifies the maintenance required to maintain these SSCs. Maintenance procedures

3-MISC-126 and 3-MISC-363 direct the winterization checks of heat trace, and freeze protection.

Operations procedures TO-040-791 and TO-040-792 direct the monitoring of temperatures for

safety SSCs.

3.14 Performance Measures

TFC-PRJ-PC-C-11 provides the method for developing, documenting, analyzing, and presenting

performance indicators, reporting analysis results, and identifying the need for corrective or

improvement actions. TOC Maintenance utilizes several performance indicators that have been

developed to monitor performance. These performance indicators are monitored and reviewed to

allow for identification of adverse trends.

3.15 Facility Condition Inspection

TFC-ESHQ-S_SAF-C-12 is the TOC procedure that integrates general worksite safety and health

inspections that are occurring on a scheduled basis into one overall inspection process.




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The PM, DSTIP, and Single Shell Tank Integrity Project are integral parts of the inspection

process for SSCs at Tank Farms, these programs help to maximize equipment operability and

reliability by eliminating hidden faults before equipment is disabled, and identify actions

necessary support the RPP mission goals with existing equipment and infrastructure.

Periodic inspection of SSCs is accomplished by field walkdowns by designated engineers in

accordance with TFC-ENG-FACSUP-P-01. When system components are inaccessible,

alternative methods of system evaluation approved by engineering management are performed.

The periodic inspections/walkdowns may include reviewing system operational testing, or

evaluating remotely obtained monitoring data when appropriate. The system walkdowns address

both material conditions and compliance aspects (including TSR (Technical Safety Requirement)

level controls) and are an essential step in evaluating SSCs for degraded conditions that affect

operability and technical obsolescence. When corrective maintenance is necessary, a work order is

generated.

The Management Observation Program (MOP) (TFC-ESHQ-AP-C-03), Management-Directed

and Required Assessments (TFC-ESHQ-AP-C-01), Employee Accident Prevention Council

activities, and Radiological surveillances are all used to identify and correct industrial safety

deficiencies, radiological protection/control deficiencies, and general housekeeping deficiencies.

MOP evaluations and Management Assessments concentrate on safety practices, work habits,

radiological control practices, and work site conditions.

DOE O 430.1B, “Real Property Asset Management,” requires the performance of Condition

Assessment Surveys (CAS) to assess the current material condition of real property. For the

Hanford Site, a list of buildings/facilities to be assessed has been developed using a graded

approach as described in DOE/RL-2012-29, “Hanford Ten Year Site Plan.” The assessment

information for each assessed item is entered into the Condition Assessment Information System

(CAIS). The Mission Support Contractor (MSC) manages the Hanford Site CAS/CAIS and

provides for the administration and execution of the CAS inspection program. The TOC provides

access to facilities and assist as necessary.

Tank Farm underground storage tanks, piping systems, and associated underground systems are

not address by the CAS Program Deficiency Standards & Inspections Methods Manual. CAS

inspection of underground tank farm systems and structures are not included in the program;

however, the DST Integrity Program includes:

Periodic DST integrity assessments (e.g., ultrasonic testing and video inspection)

Chemistry sampling and adjustments for DST corrosion control

DST structural analysis

Periodic testing, evaluation, and certification of DST support equipment such as waste

transfer lines and valve pits

Periodic testing and certification of the 242-A Evaporator Facility (e.g., Cathodic

Protection).

The integrity assessment program is being expanded to include SSTs.





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3.16 Post Maintenance Testing

TFC-OPS-MAINT-C-01 requires work be reviewed for post maintenance testing applicability.

The instructions for performing and documenting Post Maintenance Testing are included in the

work instructions when applicable. Post maintenance testing is performed to verify components

will fulfill their design function when returned to service after maintenance. This testing

comprises verification that the affected equipment (including interfaces, controls, interlocks, and

instrumentation) performs its intended functions following maintenance to ensure the original

deficiency was corrected and no additional deficiencies were created.

Post maintenance testing of safety SSCs is required for safety SSCs in accordance with

TFC-OPS-MAINT-C-01 and TFC-ENG-STD-08. General Service SSCs are evaluated to

determine the extent of or need for post maintenance testing. Post maintenance testing for minor

maintenance (e.g., repaint a step, or repair lagging) may not be applicable. More extensive

maintenance (rebuild an air compressor) may require a series of tests specified by the vendor or

engineering; therefore, a graded approach is applied to post maintenance tests for non-safety SSCs.

3.17 Integration with Regulations and DOE Orders and Manuals

The TOC has developed programs, policies, and procedures necessary to implement regulations,

DOE Orders and manuals that are applicable to the NMMP. Specific details of the program

requirements are found in the implementing documents applicable to the program. The following

is a brief synopsis’s of key interfaces with the NMMP that have not been previously discussed.

TFC-PLN-02 describes the quality assurance program using the structure of DOE O 414.1D:

Management Processes

Performance Processes

Assessment Processes.

Management process requirements are applied throughout the performance processes and

assessment processes as appropriate to the type of work being accomplished. Performance

process requirements specify the quality assurance controls for conducting the supporting work,

design, procurement and inspection and test activities. The performance process requirements are

applied to items and services. Assessment process requirements provide the oversight processes

utilized in the monitoring of all quality process activities. The assessment process requirements

include management assessment, audit, and surveillance. The assessment processes assure that

the WRPS, subcontractors, and suppliers comply with the quality assurance requirements.

TFC-PLN-41 describes the integrated processes established to perform the five core functions and

seven guiding principles of the Integrated Safety Management System (ISMS), contained in 48

CFR 970.5223-1, “Integration of Environment, Safety, and Health into Work Planning and

Execution.” It describes the methods used to establish, document, and implement safety

performance objectives, performance measures, and commitments in response to DOE program

and budget execution guidance while maintaining the integrity of ISMS.

TFC-PLN-10 describes the framework of the Tank Operations Contractor (TOC) assessment

processes for implementing the Assessment Program. The Assessment Program is an essential

part of Integrated Environment, Safety, and Health Management System (ISMS) core function 5 -

“Feedback and Continuous Improvement.”








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4.0 SOURCES

4.1 Requirements

1. 10 CFR 851, “Worker Safety and Health Program,” 10 CFR 851.21 (a)(5) and (a)(6).

2. DOE O 433.1B, “Maintenance Management Program for DOE Nuclear Facilities.”

4.2 References

1. 3-MISC-126, “Tank Farms Weekly Check of Heater and Heat Trace.”

2. 3-MISC-363, “Winterization/De-Winterization Tank Farms.”

3. 10 CFR 830.3, “Definitions.”

4. 48 CFR 970.5223-1, “Integration of Environment, Safety, and Health into Work Planning

and Execution.”

5. ASME/NQA-1, “Quality Assurance Requirements for Nuclear Facility Applications.”

6. ATS-310, Section 3.18, “Instrument Calibration.”

7. DOE G 433.1-1A, “Nuclear Facility Maintenance Management Program Guide.”

8. DOE O 413.3, “Program and Project Management for the Acquisition of Capital Assets.”

9. DOE O 420.1C, “Facility Safety.”

10. DOE O 422.1 Chg 2 “Conduct of Operations.”

11. DOE O 426.2, “Personnel Selection, Training, Qualification, and Certification

Requirements for DOE Nuclear Facilities.”

12. DOE O 430.1B Chg 2 “Real Property Asset Management.”

13. DOE O 433.1B, “Maintenance Management Program for Nuclear Facilities.”

14. DOE-0336, “Hanford Site Lockout/Tagout.”

15. DOE-0342, “Hanford Site Chronic Beryllium Disease Prevention Program (CBDPP).”

16. DOE-0359, “Hanford Site Electrical Safety Program.”

17. DOE/RL-2012-29, “Hanford Ten Year Site Plan.”

18. HNF-12125, “222-S Laboratory Documented Safety Analysis.”

19. HNF-14755, “242-A Evaporator Documented Safety Analysis.”

20. HNF-5183, “Tank Farms Radiological Control Manual.”


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21. HNF-MP-5184, “Radiation Protection Program.”

22. RPP-13033, “Tank Farms Documented Safety Analysis.”

23. RPP-7574, “Double Shell Tank Integrity Program Plan.”

24. RPP-PLAN-45082, “Implementation Plan for the Single Shell Tank Integrity Project.”

25. RPP-PLAN-59958, “Process & Control System Engineering Software & Equipment

Obsolescence Plan.”

26. TFC-BSM-CP_CPR-C-05, “Procurement of Services.”

27. TFC-BSM-CP_CPR-C-06, “Procurement of Items (Materials).”

28. TFC-BSM-CP_CPR-C-18, “Material Receipt, Storage, Issuance, Return, and Excess

Control.”

29. TFC-BSM-CP_CPR-C-19, “Controlling Spare Parts Inventory.”

30. TFC-BSM-FPM_PR-C-01, “Property Management.”

31. TFC-BSM-FPM_PR-C-10, “Use and Administration of Mobile Devices.”

32. TFC-BSM-FPM_PR-C-13, “Winterization and Snow Removal Procedure for Tank

Operations Contractor Facilities.”

33. TFC-BSM-TQ-STD-01, “Technical Staff and Technician Qualification Requirements.”

34. TFC-BSM-TQ-STD-03, “Person-In-Charge Qualification Requirements.”

35. TFC-BSM-TQ-STD-10, “Maintenance Craft Qualification Requirements.”

36. TFC-CHARTER-01, “Tank Operations Contractor Charter.”

37. TFC-ENG-DESIGN-C-06, “Engineering Change Control.”

38. TFC-ENG-DESIGN-C-15, “Commercial Grade Dedication.”

39. TFC-ENG-DESIGN-C-18, “Testing Practices.”

40. TFC-ENG-DESIGN-C-34, “Technical Requirements for Procurement.”

41. TFC-ENG-DESIGN-C-35, “Process Hazard Analysis Determination and Technique

Screening.”

42. TFC-ENG-DESIGN-C-47, “Process Hazard Analysis.”

43. TFC-ENG-DESIGN-C-56, “Modification Traveler.”

44. TFC-ENG-FACSUP-C-23, “Equipment Identification and Data Management.”















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45. TFC-ENG-FACSUP-P-01, “TOC System Engineer Program.”

46. TFC-ENG-SB-C-03, “Unreviewed Safety Question Process.”

47. TFC-ENG-SB-C-06, “Safety Basis Development.”

48. TFC-ENG-STD-02, “Environmental/Seasonal Requirements for TOC Systems,

Structures, and Components.”

49. TFC-ENG-STD-08, “Post Maintenance Testing.”

50. TFC-ESHQ-AP-C-01, “Required and Management-Directed Assessments.”

51. TFC-ESHQ-AP-C-03, “Management Observation Program.”

52. TFC-ESHQ-Q_C-C-01, “Problem Evaluation Request.”

53. TFC-ESHQ-Q_C-C-03, “Control of Suspect/Counterfeit Items.”

54. TFC-ESHQ-RP_ADM-C-11, “Joint Review Group.”

55. TFC-ESHQ-RP_RWP-C-03, “ALARA Work Planning.”

56. TFC-ESHQ-RP_RWP-C-04, “Radiological Work Permits.”

57. TFC-ESHQ-S_SAF-C-02, “Job Hazard Analysis.”

58. TFC-ESHQ-S_SAF-C-12, “Safety Inspections.”

59. TFC-OPS-MAINT-C-01, “Tank Operations Contractor Work Control.”

60. TFC-OPS-MAINT-C-03, “Maintenance Tools and Equipment Control.”

61. TFC-OPS-MAINT-C-06, “Notification and Evaluation of Out-of-Calibration Measuring

and Test Equipment.”

62. TFC-OPS-MAINT-C-07, “Control and Calibration of Measuring and Test Equipment.”

63. TFC-OPS-MAINT-C-12, “Preventive/Predictive Maintenance Administration.”

64. TFC-OPS-OPER-C-01, “Technical Safety Requirement Compliance.”

65. TFC-OPS-OPER-C-11, “Equipment Temporary Modifications and Bypasses.”

66. TFC-OPS-OPER-C-13, “Technical Procedure Control and Use.”

67. TFC-OPS-OPER-C-65, “Rolling Schedule Process.”

68. TFC-PLN-01, “Integrated Safety Management System.”

69. TFC-PLN-02, “Quality Assurance Program Description.”

















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70. TFC-PLN-04, “Property Management Program Plan.”

71. TFC-PLN-05, “Conduct of Operations Implementation Plan.”

72. TFC-PLN-10, “Assessment Program Plan.”

73. TFC-PLN-23, “Configuration Management Plan.”

74. TFC-PLN-26, “Test Program Plan.”

75. TFC-PLN-41, “Integrated Safety Management System Description.”

76. TFC-PLN-47, “Worker Safety and Health Program.”

77. TFC-PLN-61, “Tank Operations Contractor Training and Qualification Plan.”

78. TFC-PLN-83, “Assurance System Program Description.”

79. TFC-PLN-100, “Tank Operations Contractor Requirements Basis Document.”

80. TFC-POL-16, “Integrated Safety Management System Policy.”

81. TFC-POL-24, “Property Management Policy.”

82. TFC-PRJ-PC-C-11, “Performance Indicator Program.”

83. TFC-PRJ-PM-C-02, “Project Management.”

84. TO-040-791, “Obtain/Record Waste Transfer Safety-Significant SSC Temperature Data.”

85. TO-040-792, “R&C Waste Transfer Safety-Significant SSC Temperature Data.”






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Table 1. TOC Program Plans Applicable to the NMMP.

DOE O 433.1B, Section 2a

Integration with Regulations and

DOE Orders and Manuals (and

their CRDs)

TOC Program Document NMMP section

(1) The following directives

(and their CRDs)

(a) DOE O 226.1B

Implementation of DOE

Oversight Policy

TFC-PLN-01, “Integrated

Environment, Safety, and Health

Management System Plan”

TFC-PLN-41, “Integrated Safety

Management System

Description”

TFC-PLN-10, “Assessment

Program Plan”

TFC-PLN-83, “Assurance

System Program Description”

3.14 Performance Measures;

3.15 Facility Condition

Inspection

3.17 Integration with

Regulations and DOE Orders

and Manuals

(b) DOE 414.1D Quality

Assurance

TFC-PLN-02, “Quality

Assurance Program

Description”

3.10 Suspect and Counterfeit

Items



and Manuals

(c) DOE O 420.1C Facility

Safety

TFC-ENG-FACSUP-P-01,

“TOC System Engineer

Program”

TFC-PLN-23, “Configuration

Management Plan”

3.3 Planning, Scheduling, and

Coordination of Maintenance


3.7 Configuration Management

(d) DOE O 430.1B Chg 2 Real

Property Asset Management

TFC-POL-24, “Property

Management Policy”

TFC-PLN-04, “Property

Management Program Plan”

TFC-BSM-FPM_PR-C-01,

“Property Management”

TFC-BSM-FPM_PR-C-10, “Use

and Administration of Mobile

Devices”

TFC-BSM-CP_CPR-C-18,

“Material Receipt, Storage,

Issuance, Return, and Excess

Control”

3.8 Procurement

3.9 Maintenance Tool and

Equipment Control

3.15 Facility Condition

Inspection

(e) DOE O 440.1B Worker

Protection Program for DOE

Federal Employees

TFC-PLN-47, “Worker Safety

and Health Program”


3.6 Training and Qualifications







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Table 1. TOC Program Plans Applicable to the NMMP (cont.)

(f) DOE O 422.1 Conduct of

Operations

TFC-PLN-05, “Conduct of

Operations Implementation

Plan,” Attachment A – Conduct

of Operations Matrix

All

(g) (DOE O 426.2, “Personnel

Selection, Training,

Qualification, and Certification

Requirements for DOE Nuclear

Facilities.

TFC-PLN-61, “Tank Operations

Contractor Training and

Qualification Plan”


of Maintenance Personnel

(h) DOE O 458.1 Radiation

Protection of the Public and

Environment

HNF-5183, “Tank Farm

Radiological Controls Manual”



(i) DOE O 450.2 Integrated

Safety Management

TFC-PLN-01

TFC-POL-16, “Operational

Readiness Program Plan”

3.5 Maintenance Procedures;



and Manuals

DOE O 433.1B Section 2

Specific Requirements.

a. Integration with Regulations

and DOE Orders and Manuals

(and their CRDs) (2) Code of

Federal Regulations

TOC Program Document NMMP section

(a) TFC-PLN-02

(b) 10 CFR Part 830, Nuclear

Safety Management, Subpart B

Safety Basis Requirements

TFC-ENG-DESIGN-C-35

TFC-ENG-DESIGN-C-47

TFC-ENG-SB-C-01

TFC-ENG-SB-C-03

TFC-ENG-SB-C-06

TFC-PRJ-PM-C-02

3.5 Maintenance Procedures;



and Manuals

(c) Integrated Safety

Management Systems (ISMS)

provisions in 48 CFR 970.5223-

1 , Integration of Environment,

Safety, and Health into Work

Planning and Execution

TFC-PLN-41, “Integrated Safety

Management System

Description.”


(d) 10 CFR 835, Occupational

Radiation Protection

HNF-MP-5184, “Washington

River Protection Solutions, LLC

Radiation Protection Program”


(e) 10 CFR Part 850, Chronic

Beryllium Disease Prevention

Program

DOE-0342, “Hanford Site

Chronic Beryllium Disease

Prevention Program (CBDPP)”


(f) 10 CFR Part 851, Worker

Safety and Health Program

TFC-PLN-47, “Worker Safety

and Health Program”













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ATTACHMENT A - MAINTENANCE PROGRAM IMPLEMENTING PLANS/PROCEDURES

AND PROCESSES

Program Element

DOE O 433.1B CRD 2

WRPS applicable

Plan/Procedure/Process Applicable sections

(b) Maintenance

Organization and

Administration

TFC-CHARTER-01, “Tank Operations

Contractor Charter”

2.2/Figure 1

TFC-OPS-MAINT-C-01, “Tank

Operations Contractor Work Control”

4.1, 4.2, 4.3, 4.4, 4.6,

4.7, 4.8, 4.11

(c) Master Equipment List TFC-ENG-FACSUP-C-23, “Equipment

Identification and Data Management” all

(d) Planning, Scheduling,

and Coordination of

Maintenance


Operations Contractor Work Control” all

TFC-OPS-OPER-C-65, “Rolling Schedule

Process” all

(e) Types of Maintenance TFC-ENG-FACSUP-C-23, “Equipment

Identification and Data Management” all



TFC-OPS-MAINT-C-12,

“Preventive/Predictive Maintenance

Administration”

all

(f) Maintenance

Procedures

TFC-OPS-OPER-C-13, “Technical

Procedure Control and Use” all



(g) Training and

Qualification

TFC-BSM-TQ-STD-10, “Maintenance

Craft Qualification Requirements” all

TFC-BSM-TQ-STD-03, “Person-In-

Charge Qualification Requirements” all

TFC-BSM-TQ-STD-01, “Technical,

Professional, and Support Staff

Qualification Requirements”

all

(h) Configuration

Management

TFC-PLN-23, “Configuration Management

Plan” all

(i) Procurement TFC-ENG-DESIGN-C-34, “Technical

Requirements for Procurement” all

TFC-ENG-DESIGN-C-15, “Commercial

Grade Dedication” all

TFC-BSM-CP_CPR-C-05, “Procurement

of Services” all

TFC-BSM-CP_CPR-C-06, “Procurement

of Items (Materials)” all




















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ATTACHMENT A - MAINTENANCE PROGRAM IMPLEMENTING PLANS/PROCEDURES

AND PROCESSES (cont.)

Program Element

DOE O 433.1B CRD 2

WRPS applicable

Plan/Procedure/Process Applicable sections

TFC-BSM-CP_CPR-C-19, “Controlling

Spare Parts Inventory” all

TFC-BSM-CP_CPR-C-18, “Material

Receipt Storage Issuance Return and

Excess Control”

all

(j) Maintenance Tool and

Equipment Control

TFC-OPS-MAINT-C-03, “Maintenance

Tools and Equipment Control”

all

TFC-OPS-MAINT-C-07, “Control and

Calibration of Measuring and Test

Equipment”

all

(k) Suspect and Counterfeit

Items

TFC-ESHQ-Q_C-C-03, “Control of

Suspect/Counterfeit Items” all

(l) Maintenance History TFC-ENG-FACSUP-P-01, “TOC System

Engineer Program” 4.4, 4.6

(m) Aging Degradation and

Technical

Obsolescence

TFC-ENG-FACSUP-P-01, “TOC System

Engineer Program” all

(n) Seasonal Facility

Preservation

TFC-BSM-FPM_PR-C-13, “Winterization

and Snow Removal Procedure for Tank

Operations Contractor Facilities” 3-MISC-

126, “Tank Farms Weekly Check of Heater

and Heat Trace,” 3-MISC-363,

“Winterization/De-Winterization Tank

Farms,”

TO-040-791, “Obtain/Record Waste

Transfer Safety Significant SSC

Temperature Data,”

TO-040-792, “R&C Waste Transfer Safety

Significant SSC Temperature Data”

all

(o) Performance Measures TFC-PRJ-PC-C-11, “Performance

Indicator Program” all

(p) Facility Condition

Inspection

TFC-ENG-FACSUP-P-01, “TOC System

Engineer Program” 4.5

TFC-ESHQ-S_SAF-C-12, “Safety

Inspections” all

TFC-ESHQ-AP-C-03, ”Management

Observation Program” all

TFC-ESHQ-AP-C-01, “Required and

Management-Directed Assessments” all

(q) Post-Maintenance

Testing


Operations Contractor Work Control” 4.4, 4.7.2

TFC-ENG-STD-08, “Post Maintenance

Testing” all

TFC-PLN-26, “Test Program Plan” all
















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Nuclear Maintenance Management Program TFC-PLN-29, …_Nuclear... · Nuclear Maintenance Management Program Manual Document Page Issue Date Management Plan TFC-PLN-29, REV C-15 2