ML19261B887
| ML19261B887 | |
| Person / Time | |
|---|---|
| Issue date: | 12/21/1978 |
| From: | Donna Anderson, Brown R, Hale C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19261B881 | List: |
| References | |
| REF-QA-99900400 NUDOCS 7903070470 | |
| Download: ML19261B887 (13) | |
Text
.
U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900400/78-04 Program No. 51100 Company:
The Babcock & Wilcox Company Nuclear Power Generation Division P. O. Box 1260 Lynchburg, Virginia 24505 Inspection Conducted:
December 11-14, 1978
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Inspectors:
/
D. G. Anderson, Principal Inspector, Vendor Date Inspection Branch
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12 21 78 R. L. Brown, Principal Inspector, Vendor
'Date Inspection Branch i
Approved by:
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C. J. g, Vendor Inspection Branch Chief, Program Evaluation Date
- Section, Summary Inspection on December 11-14, 1978 (99900400/78-04)
Areas Inspected:
Implementation of Title 10 CFR 50, Appendix B, and Topical Report BAW-10096A including design process management, verification activities, management meeting, and action on previous inspection findings.
The inspection involved sixty-nine (69) inspector-hours on site by three (3) USNRC inspectors.
Results:
In the four (4) areas inspected, there were no deviations or unresolved items identified.
039704y 4
. DETAILS SECTION I (Prepared by D. G. Anderson and C. J. Hale)
A.
Persons Contacted
- J. D. Agar, Manager, Contract Licensing
- C. A. Armontrout, Lead Quality Assurance Engineer J. R. Burris, Supervisory Engineer H. C. Cheatwood. Jr., Coordinator of Standards R. M. Gribble, Engineer G. M. Jacks, Plant Integrator J. A. Lauer, Licensing Engineer C. D. Morgan, Manager, Technical Staff G. C. Schieck, Licensing Engineer E. A. Womack, Jr., Manager, Plant Design
- Indicates attendance at the exit meet *qq.
B.
Management Meeting 1.
Objectives The objectives of this meeting were to accomplish the following:
a.
Meet with Babcock & Wilcox (B&W) management and those persons responsible for the administration of the B&W QA Program.
b.
Describe the Licensee Contractor / Vendor Inspection Program (LCVIP) organization.
Describe the LCVIP, its implementation, and the more c.
significant changes in the LCVIP.
d.
Describe the Vendor Inspection Branch (VIB) inspection nethods and documentation.
Describe the NRC evaluation of the ASME system of inspection.
e.
f.
Summarize our previous inspections of B&W.
2.
Method of Accomplishement The preceding objectives were accomplished during a meeting on December 11, 1978.
. a.
Attendees were:
C. A. Armontrout, Lead QA Engineer L. L. Barinka, Manager, Applied Mathematics J. W. Donnell, Manager, OA Audits S. H. Klein, ftanager, QA Engineering A. L. MacKinney, Manager, QA J. H. MacMillan, Vice President D. H. Roy, Manager, Engineering J. H. Taylor, Manager, Licensing B. W. Whitaker, Manager, General Services b.
The VIB organization was described and its relationship to NRC Region IV and the NRC Headquarters component of the Office of Inspection and Enforcement.
c.
The LCVIP was decribed including its objectives, its implementation structure, and the more sigrificant program changes relative to B&W.
d.
The conduct of VIB inspections sas described and how our inspections are documented including the report, responses to reports, how proprietary information is handled, the Public Document Room, and the White Book.
The purpose, scope, and status of the NRC's two year program e.
for evaluation of the ASME inspection system as an acceptable independent third party were discussed.
f.
Our previous inspections of B&W were reviewed.
3.
cindings a.
The meeting was well attended by B&W's management and they were attentive during the presentation.
b.
B&W management was particularly interested in our evolving Design Inspection module which is aimed more at direct
" measurement" of the design process than our programmatic inspection modules in the area of design.
B&W expressed concern relating to the expertise of inspectors required to perform such an inspection. We advised B&W that we wnuld be alert to the limitations of our inspectors and utilize additional personnel, if necessary.
c.
No deviations or unresolved items were identified in this area of the inspection.
. C.
Action on Previous Insoection Findings 1.
(Closed) Unresolved Item (Report No. 78-02):
Suppliers of nuclear materials hoiding a quality system certificate (materials) are not being evaluated or audited prior to the award of the contract. This appears to be inconsistent with Regulatory Guide 1.123. This item was forwarded to NRC:HQs for resolution. The response letter from QAB/NRR dated August 29, 1978, states in part that "The QAB position regat iing the basis for source evaluation is that ASME certification of a vendor is not acceptable, at the present time, as the sole basis for vendor evaluation."
2.
(Closed) Deviation (Report Nc. 78-03): Failure to follow procedures in the development and revision of safety analysis computer codes.
The inspector reviewed the corrective action addressed in the B&W letter of response dated October 12, 1978, which related a changes to procedure NPG-0902-06, Computer Program Development and Certi fication.
This revised procedure was reviewed and becomes effective on December 15, 1978.
3.
(_ Closed) Items Identified for Further Action (Report No. 78-03):
In Section C.I.b. of the referenced inspection report, nine (9) items were identified to B&W management for their consideration.
The items related to procedural deficiencies and have been incorporated into the revision of NPG-0902-06 as indicated in their response (October 12,1978).
D.
Design Process Management 1.
0_b_,ie c_ti ve s The objective of this area of inspection was to examine the establishment and implementation of quality related procedures for the cesign process to verify that:
a.
The design process system is defined, implemented, and enforced in accordance with approved procedures, instructions, or other documentation for all groups performing safety related design activities, b.
Design inputs are properly prescribed and used for transla-tion into specifications, drawings, instructions, or proce-dures.
c.
Appropriate quality standards for items important to safety are identified, documented, and their selection reviewed and approved.
d.
Final design can be related to the design input with this traceability documented, including the steps performed from design input to final design.
e.
Design activities are documented in sufficien* detail to permit design verification and auditing.
f.
The methods ara prescribed for preparing design analyses, drawings, specifications, and other design documents so that they are planned, controlled, and correctly performed.
2.
Method of Accomolishment 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, Nuclear Power Generation Division to describe their activities relatea to the design process.
The design process system is defined, implemented, and enforced according to the following procedures:
(1) Quality Assurance Manual 19A-N.1, Section 3.0, Design Control.
(2)
?G-0412-55, Preparation of Design Specifications /
Requirements Documents; NPG-1702-03, Preparation of QA Input to the Safety Analysis Report; NPG-0405-22, Design Review; NPG-0412-11, Preparation and Processing of Technical Standards Manuals; NPG-0412-27G, Policy-Technical Standards; NPG-0413-03, Independent Design Reviews of ASME Stress Reports and Other Design Analyses; NPG-0a13-04, Policy-Independent Review of Stress Reports and Analyses; NPG-0412-58, Processing NPGD Prepared Detail Design Documents and Plant Arrangement Drawings; NPG-0412-57, Preparation of NPGD Detail Design Documents and Plant Arrangement Drawings; NPG-0414-12, Preparation of Contract and Generic Licensing Documents; NPG-0143-13, Processing Contract and Generic Licensing Documents; NPG-0405-30, Ssign/ Test Documentation and Verification; NPG-0405-21, Change Inquiry / Authorization; NPG-0403-11, Signatures on Engineering 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 Infomation Sheets; NPG-0305-03, Preparation, Distribution and Use of The Commercial Contract Information Sheets-NSS Contracts; NPG-0310-28,
. Technical Deviation List; NPG-0405-13, Plant Parameter List; NPG-0310-27, Preparation and Revision of Core Contracts Requirements List; and NPG-1303-15, Control of NPGD Manuals.
b.
Design inputs were reviewed ia the followins documents:
(1) Entering Message, Ohio Edison Company, Contract 620-0033/34, August 4,1976, which defines the scope of supply for Units 1 and 2.
(2) Commercial Contract Information Sheet, October 2,1978, and Commercial Contract Information Sheet Distribution List, File # NSS-33/34, T.2.1.2.
(3) ADL-No. 21-1000207-06, Applicable Documents List, September 22, 1978.
These design inputs were translated into tha following documents:
(1) Equipment Specifications: 08-1022-06, Equioment Specification-Reactor Vessel, March 6,1978.
(2) Drawings: 39031F2, Reuctor Vessel Assembly Specification Drawing, April 8, 1976; 209721E, Instrumentation Nozzle /
Lower Head Assembly; 209728E, Control Rod Housing Assembly Detail, July 27, 1978; 34689F, Reactor Vessel and Head Closure General Arrangement, vanuary 9,1975; 1001423, Reactor Vessel Details, May 30, 1978; 32876F7, Reactor Coolant System-Process and Instruction Diagram, November 28, 1977.
(3) Manufacturing Specification:
27-1004539-00, Core Support Assembly, July 13, 1978.
(4) External Transmittals:
EN-0EC/B&W--0039, Erie Nuclear Plant, Units 1&2-Seismic Design Criteria, February 11, 1977.
c.
The following documents were reviewed for identification and review of quality standards:
(1) 2Al-N, Nuclear Materials Standards Manual-NPGD Technical Standards Manual, A. S. Book #2772.
(2) 24-1003844, Contract Technical Requirements for Reactor Vessel, March 2,1978; 34-Ir~ 77-00, Hardware Data Sheet-Makeup Pump, February 2, 1976; 85-1002130-01, Core Contract Requirements List-Mark C Fuel, September 20, 1978; 15-1000000-01, System Description Reactor Coolant System; 48-0213-04, Quality Requirements Matrix for Reactor Vessel, March 1,1978.
d.
The inspector reviewed the steps taken in the design process from initial design input to incorporation into the final design documents:
(1) Contract for NSSS/ Erie Nuclear, Units 1&2, Ohio Edison, July 26, 1976.
(.2 ) Plant Parameter List, 37-1000010-01, Sections 1, 2, and 3; Technical Deviation List, NSS-33/34 T.2.1.1, Section 2, November 11, 1975; Task Engineer Assignments, October 10, 1978.
(3)
B-SAR-205, Standard Safety Analysis Report, Volume 1, Controlled Copy #177. PSAR-Ohio Edison Company Erie Nuclear Plant, Units 1&2, Volumes 1 and 6.
(4)
Internal Transmittals: NSS-33/34 T.3.80, Project Overview /0hio Edison Company, April 1,1977.
(.5 ) External Transmittals: Progress Report /NSSS Milestone Schedule for June 1978, Ohio Edison Company Erie Nuclear Plant, B&W NSS-33&34, July 10,1978; and Bimonthly Schedule Report-Ohio Edison Company, August 2, 1977.
e.
The following activities related to design change control were reviewed by the inspector to assure that documentation was provided in sufficient detail to permit design verification and auditing:
(_1) The following Change Inquiry / Authorizations related to design changes on the reactor vessel and reactor coolant system:
88-4033-00 May 10, 1977 88-4245-00 September 22, 1977 88-4454-00 April 5,1978 88-3921-00 March 15, 1977 88-4528-00 March 13, 1978
. 88-4298-00 February 25, 1978 88-4472-00 February 27, 1978 88-4372-00 August 1, 1978 88-3420-00 March 23, 1977 88-3256-00 September 13, 1976 88-4090-00 May 25, 1977 88-4217-00 August 12, 1977 88-4670-00 August 17, 1978 88-4725-00 October 4,1978
(.2 ) Document Release Notice (DRN), September 20, 1978.
f.
The inspector reviewed the following design analyses to assure that they are planned, controlled, reviewed, approved, and correctly performed:
(1) 2A3-N Manual, Standard Nuclear Engineering Calculations, A. S. Book #2756.
(2) Plant Parameter List, 37-1000010-01, Page 5.J., Pressurizer Level Setpoints, Item 4. Normal Operating Level.
(3) Calculation #32-2026-00, Preliminary Pressurizer Volume, Level Settings and Valve Parameters, March 24, 1975.
Calculation #32-0827-00, Reactor Coolant Syster. Hydraulics-Babcock 205,12E13.2, February 17, 1975. Calculation #88-2892-00, Reactor Coolant System / Pressurizer January 7,1976.
Calculation #88-3362-00, Pressurizer Heater Operator Control Banks, May 20, 1976.
(4) Drawing 37349F, Individual Heater Penetration Pressurizer Assembly and Details, April 18, 1975.
(5) Design Review Board: Meeting minutes of May 22,1975, August 14, 1975, and September 15, 1975; 80-0123-00, Design Review of Pressurizer Heaters, May 22, 1975.
(6) External Transn. ctals: NSS STD 205/i 3.23, Liquid Level Interlock for Pressurizer Heaters, transmitting Change Inquiry / Authorizations 88-2892-00 and 88-3362-00, July 9, 1976.
3.
Findinas In this area of the inspection, no deviations or unresolved items were identified.
_9_
E.
Exit Meeting An exit meeting was conducted with management representatives of Babcock and Wilcox at the conclusion of the inspection on December 14, 1978.
In addition to those individuals indicated by an asterisk in the Details Sections of this report, the following were in attendance:
S. H. Klein, Manager, Quality Assurance Engineering A. L. Mackinney, Qu11ity Assurance Manager G. R. Skillman, Engineering Department Staff B. W. Whitaker, Manager, General Services The inspector summarized the outstanding items and corrective actions which were reviewed during this inspection.
The inspector discussed the scope of this inspection and the fact that no findings were identified during this inspection. Management representatives acknowledged the statements of the inspector relating to this inspection.
DetailsSection II (Prepared by Ross L. Brown)
A.
Persons Contacted
- J. L. Donnell, Manager, Quality Assurance Audits
- C. M. Fletcher, Manager, Quality Control Surveillance
- These persons attended the exit meeting.
B.
Verification Activities 1.
Objectives The objectives of this area of the inspection were to verify that procedures have been established and implemented for verification activities that provide for:
a.
The assignment of qualified personnel to perform inspections, audits or other quality activities in the suppliers facility.
b.
Planning the quality verification activities.
c.
The implementation of source surveillance including inspection aucits and test control.
d.
The reporting of source surveillance activities and evaluation of these reports.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
The review of the Babcock & Wilcox (B&W) Topical Report BAW-10096A, Revision 3, dated April,1977, Sections 2, 4, 7, 12 and 18, to determine the B&W commitments relative to the verification of their suppliers quality related activities.
b.
Review of the B&W Nuclear Power Generatioa Division Quality Assurance Manual 19A-N.1 (NPGD-QAM), Section 4, Revision 05, dated August 30, 1978, to verify that the procurement documents are required to include or reference the applicable codes, standards or regulatory requirements.
c.
The review of the following C;W instruction and procedures to determine that a method has been established to assure that
. purchased materialt, equipment and services conform to the requirements set forth in the procurement documents with respect to source evaluation and selection, source inspection, documentation and evaluation of inspection results and a system to determine the continuing effectiveness of the vendor's quality program.
(1) NPGD-QAM, Section 5, Revision 02, dated August 30, 1978,
" Instructions Procedures and Drawings."
(2) NPGD-QAM, Section 7, Revision 05, dated August 30, 1978,
" Control of Purchased Material, Items and Services."
(3) NPGD-QAM, Section 12, Revision 03, dated August 30, 1978,
" Control of Measurement and Test Equipment."
(4) NPGD-QAM, Section 18, Revision 03, dated August 30, 1978,
" Audi ts. "
(5) NPGD - Administrative Manual Policies Procedures No.
NPG-1212-12, Revision 6, dated November 17, 1978
" Preparation and Processing of Procurement Documents.
(.6 ) NPGD - Operating Instructions and Section Quality Standards (0I), No. 01-1037, Revision 3, dated February 15, 1977, "QA Audit Record System."
(7) NPGD-01, No. 01-1038, Revision 1, dated February 15, 1977, " Review of Supplier's Quality Program Manual."
(5) NPGD-01, No. 01-1039, Kevision 5, dated November 7, 1977, "QA Suppler Pre-Award Evaluation."
(9) NPGD-01, No. 01-1040, Revision 3, dated June 1,1977, "QA Supplier Quality Program Audit."
(10) NPGD-0I, No. 01-1044, Revision 3, dated November 17, 1978,
" Suppliers Status List (SSL)."
(11) NPGD-0I, No. 01-1050, Revision 0, " Purchase Order or Change Order Acknowledgement."
(12) NPGD-0I, No. 01-1104, Revision 1, dated February 15, 1977, " Quality Assurance Ceficiency Reporting and Analysis System."
~
. (13) NPGD-01, No. 01-1116, Revision 0, dated October 13, 1976, " Review of SVP's" (Source Visitation Plan).
(14) NPGD-01, No. 01-1142, Revision 3, " Quality Assurance Audit Program."
(15) NPGD-01, No. 01-1000, Revision 1, " Review of QA Data Package."
(.16 ) NPGD-0I, No. 0I-1002, Revision 0, " Inspection of Large AC Vertical Shaft Motors."
(17) NPGD-01, No. 01-1003, Revision 0, " Inspection of Centrifugal Pumps."
(18) NPGD-0I, No. 0I-1012, Revision 0, " Source Inspection of Tanks, Pressure Vessels, and Heat Exchanger 2."
(19) NPGD Specification 09-1212-01.
Issue Date: January 16,1974, " Quality Assurance Program Require,nents for Nuclear Equipment." This document is part of each purchase order for nuclear material or services.
d.
The inspector reviewed the following qual'ty assi'rance records to verify that the requirements descu d iii e
B.2.a.,b. and c were implemented:
(1) These documents are relative to the reactor coolant pump supplier for one project.
(a) Purchase Order package, including the purchare order, purchase change orders, equipment specification, Specification 09-17.12-01, SVP and inspection checklist.
(b) NPGD - audit reports 75-6, 76-9, 77-11 and 78-13.
(c) S irveillance reports for 1977 and 1978.
(d) QA Da:a Package for pump casing, pump internals and motor stand that includai; material test reports, nondestructive examination reports (RT, PT,etc.),
SVP, inspection checklist and surveillance reports.
(e) Two restraining orders and the audit reports rescinding these restraining orders and authorizing
" Approval" status in the Suppliers Status List (SSL).
. (2) The pre-award audit repart for one valve supplier's facility.
This supplier is conditionally approved in the SSL.
(3) The SVP, inspection checklist and surveillance reports for one Class II vessel fabricator.
(4)
The audit report BMCO-77-10, suppliers evaluation, and followup audit reports BMC0-77-11 and BCO-78-12. This instrumentation supplier was issued an " Approval" status on the SSL.
(5)
Five (5) auditor qualifications that includes their employment history, qualification, training records and work experience sheets.
(6) Supplier Status List, dated December 1,1978.
3.
Finding During this area of the inspection no deviation from commitments or unresolved items were identified.
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