ML19253A485
| ML19253A485 | |
| Person / Time | |
|---|---|
| Issue date: | 06/22/1979 |
| From: | Brown R, Costello J, Hale C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19253A482 | List: |
| References | |
| REF-QA-99900507 51200, 99900507-79-2, NUDOCS 7909100124 | |
| Download: ML19253A485 (12) | |
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900507/79-02 Program No. 51200 Company:
Sargent and Lundy Engineers 55 East Monroe Street Chicago, Illinois 60603 Inspection at: Chicago, Illinois Inspection Conducted: June 4-8, 1979 Inspectors-77 J. R. Costello, Principal Inspector Date Vendor Inspection Branch t!79 I "
h R. L. Brown, Principal Inspector Date Vendor Inspection Branch Approved by-3MM e-f 6[#2[79 C. J. Hale, Chief, P64 gram Evaluation Section Date Vendor Inspection Branch Su.nma ry Inspection on June 4-8, 1979 (99900507/79-02)
Areas Inspected: Implementation of Sargent & Lundy (S & L) Topical Report SL-TR-1A, Revision 5, including design document control, design change control, procurement source selection, and action on previous inspection findings.
The inspection involved sixty-four (64) hours on site by two (2) USNRC inspectors.
Results:
In the four (4) areas inspected, no deviations or unresolved items were identified.
C;E: $ - #
7 909100(M,
DETAILS SECTION I (Prepared by J. R. Costello)
A.
Persons Contacted
- J. B. Adee, Jr., Quality Assurance Coordinator C. F. Brown, Mechanical Engineer J. A. Dudeck, Senior Quality Control Coordinator M. Fencke, Administrative Assistant to Head of Structural Specification Division D. W. Holder, Specification Writer R. B. Johnson, Mechanical Engineer H. J. Kwaske, Chief Structural Specification Writer P. A. Nevins, Senior Electrical Project Engineer H. L. Schmidt, Head Electrical Specification Division G. L. Sensmeier, Control & Instrument Project Engineer
- H. S. Taylor, Assistant Head, Quality Assurance Divisien R. A. Witt, Senior Structural Project Engineer J. P. Wittenauer, Electrical Engineer
- Denotes those present at exit meeting B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Report No. 79-01): Project Instructions covering project status reports do not meet the requirements of S & L General Quality Assurance Procedure GQ-3.12 on project 4391/4392/4683/4684.
To correct this problem S & L has revised Project Instruction PI-BB-1 (Revision 5, April 25, 1979) to meet the requirements of GQ - 3.12. Also, an audit (Internal Audit No. 6-71) was conducted on May 4-11, 1979, to determine if this condition existed on other projects; corrective action has been initiated on the Clinton and Marble Hill projects to correct similar problems. To prevent similar occurrences in the future S & L has issued an Inter-office Memorandum to the Project Managers dated May 16, 1979, cautioning them to specifically follow the requirements of S & L General Quality Assurance Procedures GQ-3.12 and GQ-17.01.
2.
(Closed) Deviation (Report No. 79-01): Some Project Managers are not dating their signatures on QA Record Submittal Schedules as required by S & L General Quality Assurance Pro-cedure GQ-17.01.
To correct this problem S & L has issued a Notification of Scheduled Revision for GQ-17.01 dated 4/18/79.
This notification deletes the requirement for the approver to date c :: '. -
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his signature, as S & L feels the QA Record Submittal Schedule is adequately identified by a revision identification and date.
To prevent similar occurrences in the future S & L has issued an Inter-office Memorandum to the Project Managers dated May 16, 1979, cautioning them to specifically follow the requirements of S & L General Quality Assurance Procedures GQ-3.12 and GQ-17.01.
3.
(0 pen) Unresolved Item (Report No. 79.01):
Project procedures for project 4536 do not assign responsibility for resolution and/or close out of supplier's QA program deficiencies identified by Sargent & Lundy Engineers.
Corrective action is not scheduled for completion until June 30, 1979.
C.
Procurement Source Selection 1.
Objectives The objectives of this area of the inspection were to verify that procedures have been established and implemented for the selection of qualified suppliers of services, materials, parts and components that provide for:
Requirements for evaluation of the potential supplier's a.
capability to provide items or services in accordance with the technical and quality assurance specifications of the procurement documents.
b.
Methods of evaluating potential suppliers that are consistent with applicable regulatory, code and contract requirements and should include source evaluation audits, review of historical performance, and/or review and evaluation of the supplier's QA program, manual and procedures.
Consideration of the complexity, inspectability and safety c.
significance of purchased items or services when selecting the method of source evaluation.
d.
Performance of source evaluation audits that include appropriate checklists or instructions for systematic review of the prospective supplier's QA system.
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Qualification requirements for personnel performing source e.
evaluation audits.
1.
Source selection being based on historical product performance that includes review of past procurement and operating experience with identical or similar items and is limited to relatively simple services or off-the-shelf items.
2.
Method of Accomplishment The preceding objectives were accomplished by an examination of:
Sargent & Lundy Topical Report SL-TR-1A, Revision 5.
a.
b.
Chapter 17 of the Preliminary Safety Analysis Report (PSAR) for Clinton Power Station, Amendment 21.
Chapter 17 of the Preliminary Safety Analysis Report (PSAR) c.
for Byron /Braidwood Stations, Amendment 5.
d.
Implementing procedures to satisfy Quality Assurance ProgrJm Commitments and to satisfy the intent of the objectives section.
These procedures are:
(1) General Quality Assurance Procedure GQ-4.01, Preparation, Review and Approval of Procurement Specifications, Revisions 0 thru 7.
(2) General Quality Assurance Procedure GQ-4.02, Bid Evaluation and Recommendation, Revision 4.
(3) General Quality Assurance Procedures GQ-5.02, Bid Evaluation and Recommendation, Revisions 0 thru 3.
(4) S & L Mechanical Engineering Standard ME-1.5, Instructions for Technical Review of Procurement Documents, Revision O.
(5) S&L Structural Administrative Standard SAS-40, Review of Safety Related Specifications, 4/26/79.
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(6) S & L Electrical Standard Instruction ESI-252, Review of Safety Related Procurement Documents, 10/21/78.
Documents to verify implementation of Quality Assurance c.
Program commitments and to satisfy the intent of the objectives section. The documents are as follows:
(1) Procurement Status Report, Clinton Power Station-Units 1 & 2 for period ending 3/15/79.
(2) Status of Project Specifications, Byron /Braidwood Units 1 & 2 for period 4/15/79.
(3) Procurement Specifications K2862 (6/30/77), Ilydrogen Recombiner, Amendment 1 (6/6/78); Purchase Order C14135 (9/18/78) to Rockwell International.
(4) Procurement Specification K2991 (10/6/78), Optical Isolator Cabinets; Bid recommendation-Electromax Instruments Incorporated.
(5) Procurement Specification K2896 (5/25/77), Drywell Locks & IIatches, Amendment 2 (2/23/79); Purchase Order
'C2993 to Chicago Bridge & Iron.
(6) Procurement Specification F2771,Ilangers, Supports, &
Snubbers; Purchase Order 186239 to ITT Grinnell.
(7) Procurement Specification F2827, Radiation Monitoring System; Purchase Order 213825 to General Atomics.
(8) Procurement Specification F2909, Pipe Whip Restraints; Purchase Order 222430 to Chicago Bridge & Iron.
(9) Bid Evaluations for Procurement Specifications K2862, K2991, K2896, F2771, F2827 and F2909.
(10) Specification Logs in Mechanical, Structural &
Electrical Departments.
(11) Specification Transmittal Sheets for K2862, K2991, K2896, F2771, F2827, & F2909.
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3.
Findings a.
Deviations None b.
Unresolved Items None c.
Comments It is not apparent from a sample inspection of procurement specifications that the objectives of S & L General Quality Assurance Procedure GQ-4.01 including earlier revisions are being fulfilled.
In particular, it is not always obvious that those individuals on the list of individuals required to comment have commented, or indicated that they have no comments. Also, the required date of return for comments is not always being met.
The shmple of procurement documents which the inspector examined and which gave rise to the above concerns are listed below:
(1) K2862 Hydrogen Recombiner (2) K2991 Optical Isolator Cabinets (3) K2896 Drywell Locks & Hatches (4) F2771 Hangers Supports & Snubbers (5)
F2827 Radiation Monitoring Systems (6) F2909 Pipe Whip Restraints Exit Meeting A meeting was conducted with management representatives at the conclusion of the inspection on June 8, 1979.
In addition to the individuals indicated by an asterisk in the Details Sections, those in attendance were:
L. E. Ackman, Director of Services W. A. Chittenden, Director of Engineering D. C. McClintock, Manager Electrical Department J. E. McFarland, Head, Quality Assurance Division M. Zar, Manager Structural Department S. A. Zych, Head Quality Control Division re. !.', a: f's o.i The inspector summarized the scope and findings of the inspection for those present at the meeting.
Actions taken on the findings identified in previous inspection were also discussed along with the resolutions of these findings. Management representatives acknowledged the statements of the inspector.
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DETAILS SECTION II (Prepared by Ross L. Brown)
A.
Persons Contacted C. A. Blumenthal, Project Leader, Electrical Design and Drafting C. M. Chiappetta, Senior Electrical Project Engineer M. Davis, Structural Specification Engineer D. M. Fischer, Mechanical Project Engineer
- A.
P. Gillis, Senior QA Coordinator A. Morcos, Structural Project Engineer M. F. Scannicchio, Project Leader, Mechanical Design and Drafting H. L. Schmidt, Head, Electrical Specifications Division
- Attended exit meeting B.
Design Document Contrcl 1.
Objectives To determine that approved procedures have been established and are being implemented for the control and distribution of design documents that provide for:
Identification of personnel positions or organizations a.
responsible for preparing, reviewing, approving, and issuing design documents.
b.
Identification of the proper documents to be used in performing the design.
c.
Coordination and control of design (internal and external) interface documents, d.
Ascertaining that proper documents, and revisions thereto, are accessible.
c.
Establishing distribution lists which are updated and maintained current.
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2.
Method of Accomplishment The above objectives were accomplished by:
Review of the Sargent & Lundy (S & L) Topical Report a.
SL-TR-1A, Revision S, dated October 31, 1977, Section 3.00 to determine the S & L commitments related to design document control.
b.
Review of the following General Quality Assurance Procedures (QAP) to determine if the QA program includes procedures that provide control and assigns responsibilities for the activities that affect quality.
(1) GQ-3.04 assigns the responsibility for the preparation and distribution of the design criteria to the Quality Assurance Records Section for microfilming.
(2) GQ-3.06 designates the responsibility for the approval and distribution of the approved S & L Standards that pertain to safety-related structures, systems and components.
(3) GQ-3.07 establishes the requirement and responsibility; for the preparation and distribution of a project drawing list on a monthly basis, also the distribution of approved drawings.
(4) GQ-3.09 assigns the responsibility for the distribution of foreign design documents to affected interfacing departments for comments and approval, also final distribution of acceptable documents to affected interfacings persons.
(5) GQ-3.10 describes the requirements and responsibility for planning and performing system and structure design reviews.
(6) QQ-3.11 describes the QA requirements for the preparation, review and approval of design reports.
(7)
GQ-3.12 describes the requirements and responsibilities for the preparation and distribution of project status reports, that are prepared to identify the current revision of various design documents.
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. (8) GQ-5.01 establishes the requirements and responsibilities for the preparation, review, approval and control of project instructions that compliment the requirements of the S & L quality program.
(9) GQ-6.01 describes the requiremeats and responsiblities for the preparation, approval and control of the Project Distribution List and Project File Indexes.
c.
Review of " Replication Design Criteria", Document No. DC-RN-01-MH which establishes the replication criteria for the design phase of the 4808/4923 project.
d.
Review of " Project Instruction", No. PI-MH-009, that states replicate specifications shall duplicate the technical requirements of the latest revision of the corresponding specification for project 4391/4382.
Review of the following documents to verify program implementation:
e.
(1) Project Distribution List for Project No. 4808/4923, that designates the required internal and external distribution of S & L design documents, foreign design documents and correspondence for the projects.
(2) Distribution for comments list, internal and external comments, reviewers log, transmittal letters, independent reviewers comments for Project 4808/4923 drawings representing replicate, unique, and combination of replicate and unique systems.
(a) Diesel Fuel Oil-Single System, No. M-556, Sheet 12.
(b) Essential Service Water, Reactor Bldg. - El. 377'-0", No.
M-544, Sheet 39.
(c) Cable Pans-No. E-1-3243, Rev. A, B and C.
(d) Off-Gas System-Single System-No. M-651, Sheets 3, 15 and 18.
(3) Distribution for comments list, comments, independent reviewer comments and final issue of the two (2) following specifications related to Project 4808/4923.
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. (a) Specification No. Y2909 - Pipe Whip Restraints, Addenda 1 and 2.
(b) Specification Y2815 Cable Trays and Support, Addenda 1, 2 and 3.
(4) Proj ect (4808/4923) document status report.
3.
Findings No deviations from commitment or unresolved items were identified in this area of the inspection.
C.
Design Change Control 1.
Objectives The objectives of this area of the inspection were to verify that:
Procedures have been established and implemented for controlling a.
changes to approved design documents.
b.
Design changes are:
(1) reviewed for the impact of the change (2) documented as to the action taken, and (3) transmitted to all affected persons and organizations.
The design changes are justified and subjected to review and c.
approval by the same groups or organizations as for the original design (see d. below for exceptions),
d.
When responsibility has been changed, the designated organization shall have access to the pertinent information, competence in the specific area of design, and an understanding of the requirements and intent of the original design.
2.
Methods of Accomplishment The above objectives were accomplished by:
a.
Review of the topical report Section 3.00 to determine the S & L commitments relative to design change control.
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.. b.
Review of the following procedure and instructions to verify that the program provides controls of design change.
(1)
GQ-3.13 describes the QA requirements and assigns the responsibilities for the preparation, review, approval and control of Engineering Change Notices (ECN) that pertain to safety-related structures, systems and the components.
(2) Project Instruction - PI-MH-008, which describes the processing of field initiated design change control documents.
The documents are Field Change Control Documents (FCCD) and are any one of the following:
Field Change Request (FCR), Contractor Change Request (CCR),or Field Nonconformance Report (FNR).
c.
Review of the following design document changes related to Project 4808/4923 to verify implementation of the program described in C.2.a and b.
(1) ECN-60-Containment Building Dome Liner Embedments.
(2) ECN-M8 - Miscellaneous Shop Fabricated Tanks.
(3) ECN-M30 - Code Changes.
(4) ECN status report.
(5) FCR Log.
(6) All FCRs issued during 1979.
(7) Vendor Change Requests-VCR-18, VCR-9 and VCR-10.
These change requests were issued to identify changes to replication.
(8) Response letter accepting the VCRs in C.2.c.(7).
(9) Two (2) ECNs that made addenda 1 and 2 to Specification Y2909 necessary.
3.
Findings No deviations from commitments or unresolved item were identified during this area of the inspection.
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