ML19209C798
| ML19209C798 | |
| Person / Time | |
|---|---|
| Issue date: | 07/26/1979 |
| From: | Donna Anderson, Hale C, Jerrica Johnson NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19209C786 | List: |
| References | |
| REF-QA-99900400 99900400-79-2, NUDOCS 7910180313 | |
| Download: ML19209C798 (11) | |
Text
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U. S. NUCLEAR REGULATORY COP}!ISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900400/79-02 Program No. 51100 Company:
The Babcock & Wilcox Company Nuclear Power Generation Division P. O. Box 1260 Lynchburg, Virginia 24505 Inspectiob~ Conducted:
July 17-20,1979 Inspectors:
, de Lg 7/24 /79 D. G. Anderson, Principal Inspector Da'te Program Evaluation Section Vendor Inspection Branch Q.rh. On-l' m x 7/ >4 / 79 J.(/1. Jot >r} son, Contractor Auditor Date Program Efaluation Section Vendor Inspection Branch Approved by:
' Jb) 7-N7 9 C. J. Hate, Chief, Program Evaluation Section Date Vendor Inspection Branch Summary Inspection on July 17-20, 1979 (99900400/79-02)
Areas Inspected:
Implementation of Title 10 CFR 50, Appendix B, and Topical Report BAW-10096A including design input, supplier nonconformances and corrective action, and action on previous inspection findings.
The inspection involved fifty-six (56) inspector-hours on-site by two (2)
USNRC inspectors.
Results:
In the three (3) areas inspected, one (1) deviation from commitment and two (2) unresolved items were identified.
Deviation: Supplier Nonconformances and Corrective Action-Audit Action Item Reports had not been completed or were not in the files for two vendor audits. (See Notice of Deviation, Enclosure).
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. Unresolved Items:
Supplier Nonconformances and Corrective Action-Requirements for radiation qualification were not specified in procure-ment documentation for certain safety related valves (See DetailsSection II, pa ragraph B.3.b. ).
Design Input-Applicable Document Lists (required by Topical Report BAW-10096A) have not been used for the release of all documents on the WPPSS project.
(See DetailsSection I, paragraph C.3.).
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. DETAILS SECTION I (Prepared by D. G. Anderson)
A.
Persons Contacted
- C. A. Armontrout, Quality Assurance Engineer
- E. V. DeCarli, Manager, Quality Assurance
- S. H. Klein, Manager, Quality Assurance Engineering A. F. McBride, Supervisory Engineer D. W. Renner, Licensing Engineer D..C. Winteribh, Project Manager
- Indicates those individuals present at the exit meeting.
B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Report No. 79-01): An equipment specification and a system description prepared and reviewed for a safety related system contained technical contents which did not agree with the system requirements specification.
The inspector verified that the action addressed in the BAW letter of response dated March 30, 1979, had been completed.
In particular, the errors in technical data contained in the equipment specification and the system description were corrected to agree with the system re-quirements specification. Also documentation assures that the item is not generic and training was conducted to attempt to pre-vent recurrence of this item.
2.
(Closed) Unresolved Item (Report No. 79-01): Values for pressurizer level trip setpoints in the Bellefonte FSAR were not in agreement with present calculated values.
The inspector verified that amer.d-ment 18 to the Bellefonte FSAR contains the corrected values.
C.
Design Inputs 1.
Objectives The objectives of this area of the inspection were to determine that:
a.
Procedures have been established and are being implemented that prescribe the system for control of those criteria, parameters, bases, or other design requirements upon which detailed final design is based.
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. b.
Design inputs are specified on a timely basic, their selection reviewed and approved, incorporated into the design documents, and changes in input are justified, reviewed and approved.
c.
Conmitments are properly translated into design inputs, as applicable to the following:
(1) Basic functions (2)
Performance requirements (3)
Regulatory requirements, codes, and standards (4)
Design conditions (5)
Loads (6)
Environmental conditions d.
Design requirements are specified, when applicable, relating to interfaces, materials, mechanical, structural, hydraulic, chemistry, electrical, instrumentation and control, redundancy, accessibility, fire protection, and other requirements that prevent undue risk to the health and safety of the public.
2.
l<ethod of Accomplishment The preceding objectives were accomplished by:
a.
A review of the Babcock and Wilcox Topical Report, BAW-10096A',
Section 3.0, Design Control, which summarizes the methods used by Babcock and Wilcox, fluclear Power Generation Division to describe their activities related to the design process.
The design process system is defined, implemented, and enforced according to the following procedures:
(1) Quality Assurance flanual 19A-N.1, Section 3.0, Design Control.
(2)
NPG-0412-55, Preparation 'of Design Specifications /Re-quirements Documents; NPG-1702-03, Preparation of QA Input to the Safety Analysis Report; NPG-0405-22, Design Review; NPG-0412-11, Preparation and Procestsing of Technical Standards Manuals; NPG-0412-27G, Policy-Technical Standards; NPG-0412-66, Release of Product Documentation; NPG-0412-58, Processing NPGD Prepared
~:
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. Detail Design Docurrents and Plant Arrangement Drawings; NPG-0412-57, Preparation of NPGD Detail Design Docu-ments and Plant Arrangement Drawings; NPG 0414-12, Preparation of Contract and Generic Licensing Documents; flPG 0143-13, Processing Contract and Generic Licensing Documents; NPG-0412-06, Guidelines for Preparation of
, Engineering Calculation Standards for 2A3-N Manual; NPG-0402-01, Processing of NPGD Prepared Calculations; NPG-0305-01, Preparation of Nuclear Steam Core Contract Information Sheets.
b.
A review of the Preliminary Safety Analysis Repor c, WPPSS Nuclear Project No.1,1300 Mw Nuclear Power Plant, Volume 4, Chapter 5.5.10.1, Pressurizer Design Basis, to assure that design inputs were incorporated correctly into design docu-ments, and Volume 7, Chapter 17.3, Quality Assurance During Design and Construction-Babcock and Wilcox, to identify quality assurance com:nittents for design control by WPPSS.
An identification of design inputs in the following documents; c.
(1) Proposal to WPPSS tiSSS Contract, Volume 1 Section 4.1, 3
NSSS Perfomance Suninary, and Volume 2, Table 2-8, Pressurizer Design Data, October 17, 1972.
(2) Plant Parameter List, 37-6002000003-01, Section 1.0, NSSS Performance Parameters, and Section 6.0, Pressurizer Design Data, July 26,~1976.
(3)
Core Contracts Requirements List, 85-6911000001-02, August 7, 1978.
(4)
Drawings, 35023F-8, Pressurizer General Arrangement, July 20,1978.
87374A-1, Immersion Heater, March 25, 1975.
184841E-1, Pressurizer Arrangement Long Section, April 18,1975.
184842E-2, Pressurizer Arrangement Cross Section, September 4,1975.
184849E-0, Heater Bundle Assembly and Details, February 10, 1975.
(5)
Change Inquiry / Authorizations, 88-45~;-00, Reactor Coolant System Pressurizer General Arrangement, March 31, 1978.
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. 88-4493-01, Reactor Coolant System, April 11, 1978.
88-3300-00, Reactor Coolant Systen, March 2, 1976.
88-4861-00, Reactor Coolant System Insulation, August 4, 1978.
88-4871-00, Nuclear Instrumentation / Reactor Protection System, July 11, 1978.
88-4096-00, Reactor Coolant System / Reactor Coolant Piping (excluding spray line), May 19, 1977.
88-4394-00, Pressurizer Heater Bundle, November 30, 1977.
88-4390-00, Safety Related Controls and Instrumentation, December 6,1977.
88-4341-00, Reactor Coolant System, November 3, 1977.
88-4541-00, Engineered Safety Features Actuation System, March 23, 1978.
88-2727-01, Engineered Safety Features Actuation System, January 21, 1976.
88-3679-00, Reactor Coolant System / Reactor Coolant Pumps, August 26, 1976.
(6) Calculations, 32-4307-00, Applicability of STD 1390 specification to WPPSS Task 79 Source Term Calculation File, November 29, 1976.
32-2026-00, Preliminary Pressurizer Volume, Level Settings and Valve Parameters, March 24, 1975.
d.
Assuring that commitments were translated into the following documents:
(1) Equipment Specifications, 08-1032000023-08, Pressurizer Vessel, June 30, 1978.
08-1227000023-08, Heater Bundle Assembly, July 10, 1978.
18-1092000001-02, Specification for Reactor Coolant System, June 5, 1976.
18-1447000023-01, Component Loadings for the RCS Primary Piping, Hot and Cold Leg, August 8, 1977.
18-1496000023-01, Component Loadings for the Surge Line, August 12, 1977.
08-1164000023-02, Engineered Safety Feat'ures Actuation System, February 18, 1976.
18-1449000023-00, Pressurizer Heater Bundle Loadings, September 1, 1976.
(2) Memoranda, j j 7g lg
. 620-0023/32-34/30-STD 205-FA, Component Loadings for the Pressurizer Spray Line, January 6,1977.
e.
Assuring that design requirements had been specified in the following documents:
(1) System Descriptions, 15-4028000003-05, Reactor Coolant System, Table 10, Reactor Coolant System Volume, December 8,1978.
15-4000000003-02, Engineered Safety Features Actuation System, January 21, 1976.
(2)
System Requirements Specification, 35-6026000004-00, Engineered Safety Features Actuation System, April 7,1976.
(3) Quality Requirements Matrix, 48-1294-02, Pressurizer Vessel, October 14, 1976.
3.
Findings In this area of the inspection, no deviations from commitment were identified. The following unresolved item was identified during this inspection:
The WPPSS/PSAR in Chapter 17.3, comits to following the require-cents of the Topical Report BAW-10096A, Quality Assurance Program, for all activities beginning October 31, 1974.
Revision 3 to the Topical Report requires that equipment specifications, hardware data sheets, and contract technical requirements be identified on an applicable documents list. Procedure NPG-0412-66 implements this commitment by requiring that BWNP-20120A&B, Applicable nocu-ments List, a controlled document, is used for release of certain documents.
The inspector noted during the course of this inspec-tion that for documents released prior to the effective date of Revision 3, April 18, 1977, the applicable documents list was not being used on the WPPSS project. The inspector will review, during the next i' 'oection, documents generated after the effective date of Revision 3, t6 assure that the applicable documents list is now being prepared for equipment specificatic.1s, hardware data sheets, and contract technical requirements on the WPPSS project.
9.
Exit Meeting
' An exit meeting was conducted with Babcock and Wilcox management personnel at the conclusion of the inspection on Juiy 20, 1979.
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. individuals indicated by an asterisk in the Details Sections of this report were in attendance.
The inspectors discussed the scope of this inspection and the details of the findings identified during this inspection. Management representatives of Babcock and Wilcox ackncwledged the statements by the inspectors with respect to the one (1) deviation and the two (2) unresolved items presented.
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. DETAILS SECTION II (Prepared by J. M. Johnson)
A.
Persons Contacted
- C. A. Armontrout, Quality Assurance Engineer
- J. L. Donnell, Manager, QA Audits and QC Surveillance J. C. Evans, Supervising Engineer, Plant Protection Equipment R. Fair, Supervisory Inspector D. Lee, Unit Manager, Fluid Systems
- P. J. Motiska, QA Internal Auditor G. C. Schieck, Licensing Engineer
- Denotes those present at exit meeting B.
Supplier Nonco'nformances and Corrective Action 1.
Objectives The objectives of this area of the inspection were to verify that procedures for disposition of supplier nonconformances have been established cnd implemented to assure that:
a.
Suppliers identify, control, review, and disposition items that do not meet procurement document requirements, and submit the following types of nonconformances to procurement requirements for purchaser approval:
(1) Technical or material requirements are violated; (2)
Requirements of purchaser approved documents are violated; (3)
Nonconformance cannot be corrected by continuation of manufacturing process or rework; (4)
Requirements are not met, but capability of item to function is unimpaired.
b.
Purchaser dispositions supplier submitted nonconformances and verifies supplier corrective action, which includes evaluation of cause, extent, and measures to prevent recurrence, where applicable.
2.
Mett.nd of Accomplishment The preceding objectives were accomplished by an examination of:
a.
Babcock and Wilcox Topical Report No. BAW-10096A, Section 15 (Nonconforming Materials, Parts and Components), Section 16 1178 166
. (Corrective. Action), Section 18 (Audits), Section 7 (Control of Purchased flaterial, Equipment and Services), Section 10 (Inspection), Section 4 (Procurement Document Control), Sub-section 2.2.3 (Supplier Control), and Appendix A (Compliance with Regulatory Guides and AfiSI Standards), to determine program comitments (as applicable).
b.
Babcock and Wilcox Quality Assurance llanual fio.19A-N.1, Section 2 (QA Program), Section 7 (Control of Purchased f4aterial, Items and Services), Section 15 (Nonconformances) 'and Section 16 (Corrective Action) to detemine requirements and to verify that these procedures implement program comitments.
c.
Babcock and Wilcox Administrative flanual, Procedure flPG-1703-01 (Preparation and Processing of Internal Deficiency Report and Restraint Order), and Procedure NPG-0405-05,Section VII (Contract Vatia+ ions) to determine procedural requirements and to assure that 3ese implement program commitments.
d.
Babcock & Wilcox Operating Instructions flo. 01-1037(QAAudit Record System) to determine specific procedural requirements and to assure that this procedure implements program commitments.
e.
Babcock and-Wilcox Specification 1212 (Quality Assurance Re-quirements - standard QA attachment invoked in part or in toto on safety-related procurements).
f.
Babcock and Wilcox Eqaipment Specification (Technical Document) tio.1701000584-01 (Quality Classification System) tc identify safety-related and non-safety-related items and equipment.
g.
FSAR for Project 6 and FSAR for Project 23/32, Chapter 3 (Environmental Design of fiechanical and Electrical Equipment) to identify environmental requirements for equipment.
h.
Nonconformances and corrective actions related to procurement of Electrically Actuated Relief Valves for RC System Service (i.e., Pressurizer Relief Valves):
(1)
Crosby valve supplied for Project 14:
Spdfication 1079; QA Data Package including one CVAR (Contract variation ApprovaT; Request) and the Certificate of Conformance.
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. (2)
Dresser valves supplied for Projects 6,.14,15/16, 25/26, 17/18, and 23/32:
5;3cifications; Inspection Report No. 05 and NCR (Non-conformance Report) No. 78-2 and disposition, Intaection Report No. 16 and NCR No. 77-2 and disposition; CVARs (Contract Variation Approval Requests) Nos. 87-1786-00, 87-1526-00, 87-1334-00 and their disposition; PA (Pro-curement Authorization) No. 83-762206-00; two Startup Problem Reports regarding valve RC-R2; audits of Dresser dated February 22 to February 23, 1979,.and associated AIR (Audit Item Report), January 31 to February 3,1978, and three associated AIRS (including closure of two and status of one still open), July 13 to July 15, 1977, and recommendations and status of prior AIRS; Site Problem Report Nos. SPR 143, 107, 247, 241, and others related to this valve for these and other plants.
- i. Nonconformances and corrective action related to the procurement of RC (Reactor Coolant) Pumps from Bingham-Willamette:
Audit Report No.18-13 and associated AIRS and their disposition, Audit Report No. 77-12 and associated AIRS and their disposition, Audit 79-14; Inspection Report dated March 15 to March 22,1979; NCRs 77-4 and 77-3 and their closure; CVARs 6, 8, and 12 and their disposition.
j.
Nonconformances and corrective actions related tc procurements from Bailey Meter, including Non-Nuclear Instrumentation (which includes the level indicator on the pressurizer):
Specification indicating QA requirements (Specification 1212) applicability,to some safety-related equipment and to certain component parts of the pressurizer level indicator; CVARs' Nos. 87-1930-00, 87-1931-01, 87-1928-00, and 87-3069-00; Inspecticn Report No. 27 and NCR 79-1; NCP. 78-19 and closure; Audit Report No. 78-11 and status (open) of AIR 78-11-1RB; Audit Report dated October 25, 1978, and follow-up audit and status of AIRS; Restraint Orders Nos. 76-4, 76-5, and 76-6 and their status (closed); Bailey Meter current status as an approved supplier and its basis.
3.
Findings a.
In this. area of the inspection, one (1) deviation was identified (See Notice of Deviation Enclosure).
Concerning this deviation, prior to the conclusion of the inspection, corrective action was i178 i68
. taken, which included filling in form PCS 21449 for the vendor audit files noted by the inspector as delinquent in status or lacking this form; also, auditors were instructed by management on the contents of procedure 01-1037, and to review all suppliers files to assure that all sheets are completed. Memo 19A was issued documenting the above and indicating that periodic checks will be made to assure compliance.
Because bcth corrective action and preventive action have been taken, no further response to this deviation is required.
b.
One unresolved item was identified, as follows.
There is no delineation of requirements for radiation resistance and no indication that the valve will be subject to environmental con-ditions of substantial radiation levels in the specification for Electrically Actuated Relief Valve for RC System Service (i.e., Pressurizer Electromatic Relief Valve) for two plants (Projects 6 and 14), although specifications for the same valve for Projects 12 and I per hour and 1.3 x 10g/16 do identify radiation levels of 380 rads rads total dose, plus corollary requirements.
Further review will be made at a later date to determine individual project commitments and environmental requirements relative to radiation resistance.
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