ML16341B818
| ML16341B818 | |
| Person / Time | |
|---|---|
| Issue date: | 05/20/1982 |
| From: | Fox D, Hale C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML16341B816 | List: |
| References | |
| REF-QA-99900513 NUDOCS 8206280468 | |
| Download: ML16341B818 (40) | |
Text
'10 ORGANIZATION:, TELEDYNE ENGINEERING SERVICES WALTHAM, MASSACHUSETTS-INSPECTION INSPECTION NO.:
99900513/82" 01 DATE(S)'
3/29-4/2/82 ON"SITE HOURS:
79 CORRESPONDENCE ADDRESS:
Teledyne Engineering Services ATTN:
Mr. F.'. Bailey President 130 'Second Avenue
- Waltham, MA 02254 ORGANIZATIONAL CONTACT Mr.
C.
G. Sprangers, Manager, guality Assurance TELEPHONE NUMBER:,
(617) 890-3350 PRINCIPAL PRODUCT;. Engineering and Consulting Services.
e NUCL'EAR INDUSTRY ACTIVITY: Approximately 9(@ of the staff of the
~.
Waltham, Massachusetts, facility and 30K of the gayward, California, facility are involved, in nuclear activities.
Major projects include work on Turkey Point Units 3.and 4, V.
C.
Summer Unit 1, Fermi Unit','Limerick Unit 1; and Diabl,o Canyon Unit 1.
ASSIGNED INSPECTOR:
~ '
D.
F.
F R
ctor Syst s Section (RSS) e
-0 30 4-
. ate OTHER INSPECTOR(S):
A.
L. Smith, Equipment gualification Section APPROVED BY:
C. J.
Ha e, Chief,
'RSS
~/~os Date
'I INSPECTION BASES AND SCOPE:
A.
BASES:, '10 CFR Par.t 50, 'Appendix B.'
B.
SCOPE:,
This inspection was made as a result of concerns expressed
.to NRC 'pertaining to possible defi'ciencies i.n the analysis for structural integrity of the torus catwalk and piping of the Fitzpatrick and Vermont:
Yank'ee Nuclear Power Plants; to evaluate the in-place quality assurance program; and conduct an initial management meeti'ng'.
PLANT SITE APPLICABILITY: J. A.'itzpatrick, Docket 50-333; Millstone Unit 1, Docket 50-245; Nine Mile Point Unit 1, Docket 50-220; Pilgrim Unit 1, Docket'0"293; Vermont Yankee, Docket 50-271; Diablo 'Canyon, Docket 50-275; and Enrico. Fermi 2, Docket 50-341.
tl l
I
(
ORGANIZATION:
TEL'EDYNE ENGINEERING SERVICES MALTHAM, MASSACHUSETTS REPORT NO.:
99900513/82"01 INSPECTION RESULTS:
PAGE 2 of 6 A.
VIOLATIONS:
None B.
NONCONFORMANCES:
2.
Contrary to the Criterion V of Appendix B to 10 CFR Part 50 and the Diablo Canyon Project Program Plan, QA records were not stored in a single record storage facility which meets the imposed requir'e-ments of ANSI/ASME NQA-1-1979, nor were the duplicate records stored in separate locations.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and section 3.0 of the QA Manual (QAM); design activities related to Mark I contain-ment torus hydrodynamic analyses and design modifications for the J.
A. Fitzpatrick, Millstone, Nine Mile Point, Pilgrim and Vermont Yankee Nuclear Po~er Plants were not being accomplished in accordance with the QAM.
Specific examples of thi's nonconformance are:
(a)
Hydrodynamic analyses'did not include sufficient referencing of source data, principles and assumptions to permit ready traceability as required by section 3.6.1 of the QAM.
- Further, the checker of hydrodynamic analyses did not perfo'rm the duties prescribed in 'section 3.6.2 -of the: QAM as requir'ed by section 3.6. 1 of the QAM.
(b)'alculations exhibiting the signatures of the originator, checker and the design veri'fier were aot treated with the status of a QA record as required by section 3.6.3 of the QAM.
3.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and the Project Quality Assurance Program (PQAP) for the J.
A. Fitzpatrick, Millstone, and Vermont Yankee Nuclear Power Plants, activities affecting quality regarding Design/Analysis Coritrol, Project Personnel Assignment,'and Project General (Engineering)
Control were not accomplished in accordance with prescribed pr'ocedures in that the required procedures were either not imposed or not being implemented on the above projects.
A
I ~
,.ORGANIZATION:
TELEDYNE ENGINEERING SERVICES MALTHAM, MASSACHUSETTS OR NO.:
99900513/82-01 RESULTS:
PAGE 3 of 6 5.
Contrary to Criterion V of, Appendix B to 10 CFR Part 50 and the PgAP's, for the Fermi 2, Millstone and,Vermont Yankee'projects, audits were not accomplished within the specified intervals, not were they. waived in accordance with the prescribed conditions and requirements, Contrary to Criterion V of Appendix B to 10 CFR Part 50 and "
Section 17 of the JAM, P(AP's.for eight projects contained a
'equirement to retain audit records for a period of 1 year.,
rather tha'n for 6 years as required by the JAM.
C.
.UNRESOLVED ITEMS:
Xone D..
OTHER FINDINGS OR COMMENTS:
I L
1.
Management Meeting " The purpose,,scope, and nature of the licensee, Contractor and Vendor Inspection Program were reviewed with the President of Teledyne'ngineering Services (TES) and the equality
, Assurance Manager.
The concerns expressed to NRC with resp'ect to possible errors and deficiencies in the hydrodynamics load analyses of General Electric (GE) Mark I containment torus components, and in the subsequent design of related component
- supports, were outlined.
The format, content, dissemination and publication of NRC inspection reports, and TES responses
- thereto, were discussed in detail.
24 Possible Analytical Deficiencies -.An inspection was conducted to determine the validity and safety significant of concerns expressed to NRC that the use of unqualified individuals, inaccurate analy-tical models,'rroneous inpu't to structural calculations and excess management schedular press'ure could result in possible deficiencies in'he analyses for structural integrity,- and i.n the subsequent design of internal and external component supports for the torus and its associated catwalks and piping of the Fi'tzpatrick
.-'nd Vermont Yankee Nuclear Power Plants.
Review of TES records, and interviews with cognizant personnel, indi-
, cate that TES was contracted by the owners of the Fitzpatrick, Millstone Unit 1, Nine Mile Point Unit 1, Pilgrim Unit 1 and Vermont Yankee Nuclear Power Stations, 'in 1975-1976, to provide consulting services and to perform certain.analyses and design.
ORGA'NIZATION: -TELEDYNE ENGINEERING SERVICES QALTHAM, MASSACHUSETTS REPORT NO.:
99900513/82-01 INSP ECTION RESULTS:
PAGE 4 of 6 modifications pertaining to the torus of their Mark I containments.
Some design modifications have already been supplied to and incorporated by the affected plants;
- however, the total cont~act effort is not scheduled for completion unti.l late August 1982
'eview'f employment training, and qualification records, and '.
interviews with selected engineering, management, and "contract" personnel=,
di.d not 'confirm the concerns that unqualified individuals were employed to do this work nor that TES management subjected the analysts and. designers to schedular pressures such that the quality of their work was compromised.
However, the NRC inspector noted that TES did not have'documented instructions or procedures to assure that the technical qualifi-cations (education, training; and related experie'nce) claimed by newly hired permanent or contract employees conduc'ting safety-related activities, was verified, stored with the status of a gA
- record, or that appropriate corrective action was taken when anomalies or inconsistencies were uncovered.
TES management stated that appropriate procedures. would be developed and implemented prior to June 30, 1982.
This item will be followed during future inspections.
Detailed examination of the structural
- analyses, the resulting design modification drawings and their supporting stress calcula-
- tions, and interviews with cognizant personnel, indicate that the allegations relative to use of inaccurate analytical models and erroneous input data to structural calculations were based on factual observations made during a 4-month period in ear'ly 1981; Mith respect.to the use of inaccurate analytical
- models, the NRC inspector determined that the analysts:
(1) used the structural,ly similar Millstone torus drawing to obtain needed dimensions as inputs to Pilgrim hydrodynamic scoping and analyses since all requisite Pi'lgrim data was not available at the time; (2) changed the analysis te'chniques from a dynami'c analysis to an allegedly equivalent static analysis without documented
.justification;
'J 'I
ORGANIZATIQN:
TELEDYNE ENGINEERING SERVICES
- WALTHAM, MASSACHUSETTS EPORT NO.
99900513/82-01 RESULTS:
PAGE 5 of 6 L'3) used preliminary and undocumented hydraulic forces as inputs
. to the calculations; (4) did not'ocument the sources of design inputs nor assumptions in the calculation packages.
TES management stated that:
(1) the'se deficiencies are unique to w'ork related to the, identified plants and, therefore, are not generic in nature; and (2) the proper Pilgrim di'mensional data has already
. been incorporated into Pilgrim calculations.
In response to nonconformance B.2.above, TES committed to the following corrective actions:..(1) the engineering. justification for using a static analysis method would be documented; (2),al'1 affected ca'lculations would be redone using the'atest GE-published hydraulic
,forces and applicable analyses methodology; (3) sources of design
'nputs and assumptions would be documented in the calculation packages; (4) all resulting design modification drawings
.and supporting stress calculations, including those previously transmitted.
to the affected plants would be'eviewed and revised as needed.
The above actions will'e completed by August 31, 1982; One other nonconformance was identified in this area of the inspec-tion.
(See item BE 3 above.)
This area will be further examined during a'future inspection.
Furthermore, the NRC inspector noted that Revision 0 of Technical Engineering Procedures TEP-2-004, TEP-3-002, TEP-3-003, TEP-6-008, and TEP-7-004 were not reviewed and approved by the gA Manager as
'equired by sectio~
- 3. 2. 1 of 'the.(AM as evidenced by the lack.of
~
signature of the gA Manager on the. subject procedures.
Since later pevisions of these, and other procedures, were reviewed in accordance with the JAM, and since the gA Manager. agreed to document his review and approval of the subje'ct procedures, no
. nonconformance was identified.
This item will.be followed in a future inspecti,on.
H 3'.
gA Program Evaluation - The TES Corporate Policy Manual, guality Assurance
- Manual, unique PgAP's, and the related detailed imple-menting procedures governing the areas of gA Program, organization,
~
~
,ORGANIZATION:.'TELEDYNE ENGINEERING SERVICES
~ :
MALTHAM, MASSACHUSETTS t
REPORT/
NO.:
99900513/82-01 INSPECTION RESULTS:
'I PAGE 6 Of' engineering control, procurement control, gA records, and audits were reviewed to determine that they were consistent with.the quality and technical requirements that have been imposed on TES.
The documentation of completed wor k in these
- areas, con-sisting of training records for 14 individuals, 1 manage-ment evaluation. of, tpe gA program, 8 internal gA audit files,'
external gA audit files, qualification records for 2 audit team leaders, 4 purchase orders for TES services, 5 TES purchase orders to subcontractors, 3 drawing files, and applicable gA records, were examined to verify program imple-mentation.
Three nonconformances were identified in this area of the inspection.
(See items B.l, B.4, and B.5 above.)
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V Docket No. 99900513/82-01 UN 1 l. 19%
Teledyne Engineering Services.
ATTN:
Hr; F.
C.. Bailey President 130 Second Avenue Maltham, tQ 02254.
Gentlemen:'his refers to the inspection conducted by Hr. D. F., Fox of this office
. on March 29.-April 2, 1982,,of your facility at Maltham, Massachusetts, and to the 'discussion of our findings with you and members of your staff at the conclusion of the inspection.
This inspection
'was made as a result of concerns expressed to NRC pertaining to possible'eficiencies in. the. structural analyses of the torus catwalks and piping of the Fitzpatrick and Vermont Yankee "Nuclear Power Plants.
Area's examined during this inspection and our findings are discussed in. the enclosed report.
Within these
- areas, the inspection consisted of an examination of procedures and representative
- records, interviews with personnel, and observations by the inspector.
During this inspection it was found that you failed to meet certain NRC requirements.
The specific findings and references to the pertinent requirements are identified in the enclosures to this letter.
Please provide us within 30 days from the date of this letter a written statement containing:
(1) a description of steps that have been or will be taken to correct'hese items; (2) a description of steps that have been or will be taken to prevent recurrence; and
{3.) the dates your corrective actions and preventive measures were or will be completed.
Consideration may be given to extending your response time for good cause shown.-
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c Teledyne Engineering Services The response requested by this letter is not subject to the clearance procedures of the Office of Management and Budget as required by the Paperwork Reduction Act of 1980, PL 96-511.
In accordance with 10 CFR 2.790 of the Commission's regulations, a copy of this letter and the enclosed inspection report'will.be placed in the NRC's Public Document Room; If this report contains any information that you believe to be exempt from disclosure under.10 CFR 9.5(a)(4), it.is necessary that you (a) notify this office by telephone within 10'ays from the date of this letter of your intention to file a request for withholding; and (b) submit within 25 days from the date of this letter a written application to this office to withhold such.information.
If your receipt of this letter has be n delayed such that less than 7 days are available for your review, please notify this office promptly so that a new due date may be established.
Consistent with. section 2.790(b)(1),
any such application must be accompanied by an affidavit. executed by the owner of the information which identifies the'document or part sought to be withheld, and which contains a full statement of the reasons on the basis which it claimed; that the information should"be withheld from-'public disclosure.
This section further requires the'tatement to'address with specificity'he considerations listed 'in 10 CFR 2.790(b)(4).
The information sought to be withheld shall be incorporated as far. as possible into a separate part of the affidavit.
If we do not hear from 'yo'u in this.regard within'he specified periods noted above, the report will be placed in the Public DocumentRoom.
I Should you have any questions concerning this inspect'ion,.
we will be pleased to discuss them with you.
'l Sincerely, "Qrlgl-..al Slgnod b+
U, PQTAPQVS"
,Uldis Potapovs, Chief Vendor Programs Branch
Enclosures:
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Appendix A - Notice of Nonconformance 2.
Appendix B - Inspection Report No. 999005i3/82-01 3.
Appendix C - Inspection Data Sheets (12 pages) bcc:
IE Files AEOD QAB NRC:PDR Reg; Administrators, I, II, III, IV,V EHJohnson, RIV os~'cE/I R,4AMf:Pl QA ~ E P*
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